High-Voltage Junction Box Ground Bus Bar for Radiated Noise Shielding
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Solution Overview
Problem
High-voltage junction boxes in electric vehicles face challenges in effectively absorbing radiated noise due to the high resistance of traditional ground wires, which can compromise shielding capabilities.
Innovation Solution
A high-voltage junction box design featuring a ground bus bar that allows surface grounding and has low wiring resistance, enhancing noise absorption and shielding capabilities while maintaining a lightweight and cost-effective structure using non-metallic materials like shielding plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a ground wire is used to absorb radiated noise, then noise absorption is achieved, but shielding capability deteriorates due to high resistance
Solution Approach 1:
The patent changes the key parameter of grounding resistance by replacing the traditional ground wire with a ground bus bar that provides surface grounding. This transitions from high-resistance point contact to low-resistance surface contact, simultaneously improving noise absorption and maintaining shielding capability.
Solution Approach 2:
The patent substitutes the mechanical wire-based grounding system with a bus bar-based surface grounding system. This replacement changes the physical configuration from linear wire contact to planar surface contact, achieving lower resistance and better electromagnetic compatibility.
2Reliability
If aluminum materials are used for high voltage junction box, then conductivity and shielding efficiency are improved, but weight and cost increase
Solution Approach 1:
The patent changes the material parameter from metal (aluminum) to non-metallic material, achieving weight reduction while compensating for conductivity and shielding performance through the ground bus bar surface grounding design.
Solution Approach 2:
The patent uses non-metallic materials for the housing while incorporating a ground bus bar for electrical grounding, creating a composite structure that combines the advantages of both material types - lightweight housing with effective grounding capability.
3Weight of moving object
If non-metallic materials are used for housing, then weight and cost are reduced, but conductivity and noise absorption capability decrease
Solution Approach 1:
The patent introduces a ground bus bar as an intermediary element that mediates between the non-metallic housing and the grounding requirement. The bus bar provides the necessary electrical conductivity and noise absorption capability that the non-metallic material alone cannot provide.
Solution Approach 2:
The patent segments the grounding function from the housing structure by adding a separate ground bus bar component. This allows the housing to remain lightweight and non-metallic while the bus bar specifically handles the electrical grounding and noise absorption functions.
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 proposed design significantly improves the absorption of radiated noise and maintains effective shielding, even when coupled with a vehicle chassis, thereby enhancing the overall performance and reliability of high-voltage electrical systems in electric vehicles.
Implementation Method 1
at least one ground bus bar installed in the housing and configured to allow the at least one female connector to contact a vehicle body
Implementation Method 2
the shielding plate, and at least a portion of the shielding plate is exposed at the coupling portion
Data Source
AI summary
A high voltage junction box in a vehicle is powered by an electric motor. The high voltage junction box includes a housing made of a non-metallic material, the housing having a female connector installation hole, a housing cover made of a non-metallic material, a female connector disposed in the female connector installation hole, and a ground bus bar disposed at the housing and configured to connect the female connector to a vehicle body. The high voltage junction box improves the capability of absorbing radiated noise through a ground bus bar that allows surface grounding and has low wiring resistance.