High-Voltage Junction Block Sealing and Shielding for EV Bus Bars
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Solution Overview
Problem
High voltage junction blocks in electric vehicles face issues with moisture ingress and noise leakage due to external moisture flowing into bus bars and noise generated from electrical components being leaked to the outside.
Innovation Solution
A high voltage junction block design featuring a block housing, a bus bar, a sealing member made of rubber, and a shield plate made of a metallic material with elastic transformation capabilities, which together prevent moisture ingress and noise leakage by forming a sealed and noise-insulating interface with the inverter housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the high voltage junction block and inverter are connected through a bus bar, then electric power can be supplied to various electrical devices, but noise generated from the motor and electrical devices is leaked to the outside
Solution Approach 1:
A shield plate is introduced as an intermediary component between the bus bar connection and the external environment. The shield plate blocks noise generated from the motor and electrical devices from being leaked to the outside, while allowing electric power to be transmitted through the bus bar connection.
2Power
If the high voltage junction block and motor are connected through the bus bar, then electric power can be transmitted, but external moisture flows into the bus bar causing corrosion and short-circuits
Solution Approach 1:
A sealing member is introduced as an intermediary component between the high voltage junction block and the external environment. The sealing member surrounds the bus bar and prevents external moisture from flowing into the connection area, while allowing electric power to be transmitted through the bus bar to the motor and electrical devices.
3Reliability
If a sealing member is provided to surround the bus bar, then moisture protection is improved, but the structure becomes more complex
Solution Approach 1:
The sealing member is designed as a flexible sealing structure that surrounds the bus bar. This flexible sealing approach provides effective moisture protection while maintaining relatively simple structural implementation compared to rigid sealing systems.
4Object-generated harmful factors
If a shield plate is provided between the block housing and sealing member, then noise leakage is prevented, but the device complexity increases
Solution Approach 1:
A shield plate is introduced as an intermediary component between the block housing and sealing member. The shield plate effectively blocks noise leakage from the electrical components, while being integrated into the existing housing structure to minimize overall device complexity.
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
The design effectively prevents external moisture from entering the bus bar and electrical components while blocking noise from escaping, enhancing the protection and performance of the high voltage junction block and inverter system.
Implementation Method 1
a shield plate made of a metallic material with elastic transformation capabilities, which together prevent moisture ingress
Implementation Method 2
a shield plate provided between the block housing and the sealing member, and protecting noise generated from the electric power supply target body from being leaked to the outside
Data Source
AI summary
A high voltage junction block includes a block housing accommodating a circuit module distributing high voltage, a bus bar extending from the block housing, and supplying electric power to an electric power supply target body, a sealing member surrounding a circumference of the bus bar, and protecting moisture from flowing into the bus bar and a terminal of the electric power supply target body electrically connected to the bus bar, and a shield plate provided between the block housing and the sealing member, and protecting noise generated from the electric power supply target body from being leaked to the outside.