EV Charger Substrate Layout for Electromagnetic Shielding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrified vehicles face increased complexity and weight due to the need for filters to suppress noise currents from step-down converters, hindering size reduction.
Innovation Solution
The vehicle design includes a first substrate with electromagnetic wave-generating elements below a second substrate without such elements, shielded by a storage case and cooled by a cooling passage, to suppress electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter is added to suppress noise current from the step-down converter, then the performance of the auxiliary device is protected, but the number of components increases and the circuit becomes complicated
Solution Approach 1:
The patent extracts the electromagnetic wave generation function into a separate first substrate, isolating it from other components. This substrate is specifically designed to contain only electromagnetic wave generating elements, allowing the noise issue to be addressed independently through spatial separation rather than adding filters to existing circuits.
Solution Approach 2:
The patent implements a nested structure where the first substrate containing electromagnetic wave generating elements is placed inside a storage case, which itself is positioned within the front storage space. This nested arrangement allows multiple functions (EM wave containment, structural support, spatial organization) to be integrated without increasing overall complexity.
2Object-affected harmful factors
If a filter is added to suppress noise current, then electromagnetic interference is reduced, but the vehicle size and weight cannot be reduced
Solution Approach 1:
The patent converts the harmful electromagnetic waves into a beneficial shielding effect by strategically positioning the first substrate containing EM wave generating elements below the second substrate. The second substrate and storage case walls act as shields that redirect and contain the electromagnetic waves, transforming the potential interference into a controlled electromagnetic environment.
Solution Approach 2:
Instead of addressing electromagnetic interference through traditional filtering methods in the electrical domain, the patent solves the problem by changing to the spatial dimension. The vertical stacking arrangement (first substrate below, second substrate above) and the storage case positioning create three-dimensional electromagnetic wave management, reducing interference without adding weight-intensive filter components.
3Adaptability or versatility
If electromagnetic wave generating elements are placed in the front storage space, then the charger functionality is achieved, but electromagnetic waves interfere with other vehicle systems
Solution Approach 1:
The patent applies local quality by creating distinct zones within the front storage space. The first substrate area is designated for electromagnetic wave generation (charger functionality), while the area above it (second substrate and storage case) serves as an electromagnetic shielded zone. This localized functional separation allows the charger to operate without interfering with other vehicle systems in adjacent areas.
Solution Approach 2:
The second substrate acts as an intermediary between the electromagnetic wave generating elements and other vehicle systems. Positioned above the first substrate, it mediates the electromagnetic waves by absorbing and redirecting them, preventing direct interference with other systems while allowing the charger to maintain full functionality below.
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 configuration reduces electromagnetic interference while maintaining a compact vehicle design by shielding and cooling, enhancing electromagnetic wave shielding efficacy.
Implementation Method 1
since the second substrate and a wall surface of the case are present above the element being a generation source of electromagnetic waves, the electromagnetic waves are shielded to some extent
Implementation Method 2
a cooling passage through which a cooling medium from the radiator flows may be disposed between the first substrate and the second substrate in the storage case
Data Source
AI summary
Electrified vehicle includes a battery mounted on the electrified vehicle, a driving device having a traction motor disposed in a front storage space inside the hood in front of the electrified vehicle, a power control unit disposed in an upper portion of the driving device in the front storage space to drive the motor, and a charger disposed on the power control unit in the front storage space to charge the battery with electric power from an external power source. The charger includes a first substrate having an element being a generation source of electromagnetic waves, at least one second substrate having no element being a generation source of electromagnetic waves or having an element having a small influence as a source of electromagnetic waves, and a storage case for housing the first substrate and the second substrate, and the first substrate is disposed below the second substrate.