EV Battery Shielding via Embedded Metal Inserts
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Solution Overview
Problem
Electric vehicles using batteries as a power source face challenges with electromagnetic interference, where electromagnetic waves from components like the motor and current control circuits can affect other electrical components, and existing shielding methods are costly and time-consuming, with risks of electric short circuits from conductive members in confined spaces.
Innovation Solution
A frame structure with metal side members and a floor panel shields the battery unit from electromagnetic waves, using embedded metal insert members and a metal under cover to create a comprehensive electromagnetic shielding system without conductive members inside the battery case, enhancing shielding effectiveness while preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If electromagnetic shield paint is applied to the battery case surface, then electromagnetic shielding effectiveness is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent extracts the electromagnetic shielding function from the battery case surface paint and relocates it to a separate shield member (such as a metal plate or mesh) that is positioned between the battery modules and the battery case. This separation allows the shielding function to be achieved without applying paint to the entire battery case surface, thereby reducing manufacturing time and complexity while maintaining shielding effectiveness.
Solution Approach 2:
The patent introduces an intermediary shield member (metal plate, mesh, or foil) that acts as a mediator between the battery modules and the battery case. This intermediary structure provides electromagnetic shielding through its inherent conductive properties, eliminating the need for time-consuming paint application processes while achieving the desired shielding effect.
2Object-affected harmful factors
If electromagnetic shield paint is applied to the battery case, then electromagnetic shielding effectiveness is improved, but manufacturing cost increases due to expensive paint and additional processes
Solution Approach 1:
The patent extracts the electromagnetic shielding function from the battery case surface paint and relocates it to a separate shield member (such as a metal plate or mesh) that is positioned between the battery modules and the battery case. This separation allows the shielding function to be achieved without applying paint to the entire battery case surface, thereby reducing manufacturing time and complexity while maintaining shielding effectiveness.
Solution Approach 2:
The patent employs inexpensive shield members such as metal plates, meshes, or foils that can be easily manufactured and installed. These simple conductive structures provide effective electromagnetic shielding at a fraction of the cost of specialized electromagnetic shield paint, making the overall manufacturing process more cost-effective.
3Object-affected harmful factors
If conductive members are arranged inside the battery case for shielding, then electromagnetic shielding effectiveness is improved, but the risk of electric short circuit increases
Solution Approach 1:
The patent extracts the electromagnetic shielding function from the battery case interior and relocates it to a separate shield member positioned between the battery modules and the battery case. This spatial separation eliminates the risk of conductive members inside the battery case causing short circuits, while the shield member itself provides effective electromagnetic shielding due to its conductive properties.
Solution Approach 2:
The patent introduces an intermediary shield member (metal plate, mesh, or foil) that acts as a mediator between the battery modules and the battery case. This intermediary structure provides electromagnetic shielding through its inherent conductive properties, eliminating the need for time-consuming paint application processes while achieving the desired shielding effect.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively shields both the battery unit's components from external electromagnetic interference and prevents internal electromagnetic wave radiation, ensuring safety and reducing costs by eliminating the need for expensive paint-based shielding and conductive components, thereby enhancing the reliability and efficiency of electromagnetic shielding in electric vehicles.
Implementation Method 1
a floor panel made of metal provided on the frame structure, a battery unit including a battery case arranged between the pair of side members on the undersurface side of the floor panel, the battery case containing therein battery modules and electric components electrically connected to the battery modules, and the upper side of the electric components being electromagnetically shielded by the floor panel
Data Source
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AI summary
A battery unit (14) is provided under a floor panel (70). The battery unit (14) is arranged between a pair of right and left side members (31, 32). The battery unit (14) is provided with a battery case (50). The battery case (50) includes a tray member (51) and cover member (52). Electric components are contained in the battery case (50). Beam members (101, 102, 103, 104) made of metal are attached to the tray member (51). Both end portions of these beam members are supported by the side members (31, 32). The tray member (51) includes a resin and insert members (200) made of metal provided inside the resin. The insert members (200) include metal plates arranged on the front side and rear side of the electric components.