Nested Busbar Electrical Connection Box for EMI Shielding
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Solution Overview
Problem
Electrical connection boxes with high-voltage electric wires require a metal casing for electromagnetic noise protection, which limits their size reduction.
Innovation Solution
Incorporating a negative busbar that surrounds a positive busbar and fuses within a metal casing, with the negative busbar and metal casing working together to block electromagnetic noise, allowing for a thinner casing and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metal casing is provided for electromagnetic noise protection, then noise protection is improved, but the size of the electrical connection box increases
Solution Approach 1:
The positive busbar is nested within the negative busbar, creating a compact concentric structure. This nesting arrangement allows the electromagnetic shielding function to be integrated within the existing busbar configuration rather than requiring an additional separate shielding layer, thereby maintaining noise protection while minimizing the overall volume of the electrical connection box.
Solution Approach 2:
The metal casing serves multiple functions: it provides structural containment for the busbars and fuses, and simultaneously acts as an electromagnetic shield. By making the casing perform both structural and shielding roles, the design eliminates the need for separate dedicated shielding components, thus reducing the overall size while maintaining effective electromagnetic noise protection.
2Volume of stationary object
If the metal casing is made thinner to reduce size, then the volume is reduced, but the electromagnetic noise protection capability deteriorates
Solution Approach 1:
The positive busbar is positioned inside the negative busbar in a nested concentric arrangement. This configuration creates inherent electromagnetic shielding through the surrounding negative busbar structure, which protects the positive busbar without requiring a thick metal casing. The nested structure provides effective noise protection while enabling a thinner overall casing design.
Solution Approach 2:
The high-voltage positive busbar, which generates electromagnetic noise, is surrounded by the negative busbar that acts as a shield. The very structure that carries the noisy signal also provides the shielding environment, converting the potential harm of electromagnetic radiation into a beneficial self-shielding effect that reduces the need for thick protective casings.
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 configuration enables a smaller electrical connection box design while maintaining effective noise protection, enhancing installation flexibility in vehicles.
Implementation Method 1
the negative busbar and metal casing working together to block electromagnetic noise
Data Source
AI summary
An electrical connection box (1) including: a metal casing (10); a positive busbar (30) housed in the casing (10); and a negative busbar (20) housed in the casing (10), and formed so as to surround the positive busbar (30).