Metal Shell Cable Shield for Electric Vehicle Inverter

Solution Overview

Problem

Existing shield structures for conductor cables in electrically driven vehicles, such as those using braided conductors, face challenges in manufacturing and cost when the conductor cables are short, particularly when a rotating electrical machine and inverter are contiguous, leading to inefficiencies in magnetic field shielding.

Innovation Solution

A shield structure employing a metal shell that covers the conductor cable and terminal blocks, arranged across cases to prevent magnetic field leakage, reducing costs and enhancing productivity without the need for braided conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a braided conductor is used to shield the conductor cable, then magnetic field shielding performance is improved, but manufacturing difficulty and cost increase when the conductor cable is short

Engineering Contradiction:

Improvemagnetic field shielding performanceVSAvoidmanufacturing difficulty

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The shield structure is divided into multiple metal shells (first metal shell and second metal shell) that are arranged in sequence along the conductor cable. Each metal shell covers a specific section, allowing modular assembly and easier manufacturing compared to a continuous braided conductor structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the expensive and difficult-to-manufacture braided conductor with simpler, more cost-effective metal shells. These metal shells can be easily fabricated and assembled, significantly reducing manufacturing cost and difficulty while maintaining adequate shielding performance for short conductor cables.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Object-affected harmful factors

If a braided conductor is used to shield the conductor cable, then magnetic field shielding performance is improved, but cost increases

Engineering Contradiction:

Improvemagnetic field shielding performanceVSAvoidcost

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent replaces the expensive and difficult-to-manufacture braided conductor with simpler, more cost-effective metal shells. These metal shells can be easily fabricated and assembled, significantly reducing manufacturing cost and difficulty while maintaining adequate shielding performance for short conductor cables.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The shield structure is divided into multiple metal shells (first metal shell and second metal shell) that are arranged in sequence along the conductor cable. Each metal shell covers a specific section, allowing modular assembly and easier manufacturing compared to a continuous braided conductor structure.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If a braided conductor is used to shield the conductor cable, then magnetic field shielding performance is improved, but productivity decreases

Engineering Contradiction:

Improvemagnetic field shielding performanceVSAvoidproductivity

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The shield structure is divided into multiple metal shells (first metal shell and second metal shell) that are arranged in sequence along the conductor cable. Each metal shell covers a specific section, allowing modular assembly and easier manufacturing compared to a continuous braided conductor structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the expensive and difficult-to-manufacture braided conductor with simpler, more cost-effective metal shells. These metal shells can be easily fabricated and assembled, significantly reducing manufacturing cost and difficulty while maintaining adequate shielding performance for short conductor cables.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 metal shell arrangement effectively shields magnetic fields, suppresses electromagnetic noise, and is suitable for short conductor cables, reducing manufacturing difficulties and costs while maintaining effective shield performance.

Implementation Method 1

a metal shell that is arranged across the first case and the second case and covers at least part of a periphery of the conductor cable

Methodology Applied

Scientific EffectMagnetic field shielding: Faraday Cage

Data Source

PatentUS8939795B2Shield structure of conductor cable and electrically driven vehicle

Publication Date: 2015.01.27 TOYOTA JIDOSHA KK

AI summary

A shield structure of a conductor cable includes a first case that accommodates a rotating electrical machine, a first terminal block that is provided on the first case, a second case that accommodates an inverter, a second terminal block that is provided on the second case, a conductor cable that electrically connects the first terminal block and the second terminal block to each other, and a metal shell that is arranged across the first case and the second case and covers at least part of a periphery of the conductor cable.