Vehicle Rear Bulkhead Electromagnetic Shielding Structure
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Solution Overview
Problem
The existing structures for mounting power supply devices in vehicles face challenges in preventing electromagnetic interference from affecting the cabin while maintaining a sufficient crush stroke during rear-end collisions, as they either require bulky metal casings for shielding or allow direct emission of electromagnetic waves into the cabin due to through-holes in the bulkhead.
Innovation Solution
A structure featuring a rear bulkhead with a framework reinforcement unit and an electromagnetic wave shield unit that covers the front surface of the power supply device, allowing the device to be positioned in the front area of the rear trunk without a metal cover, while the bulkhead's metal material blocks electromagnetic waves and maintains a long crush stroke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the power supply device is covered with a metal casing for electromagnetic shielding, then electromagnetic interference is prevented, but the size of the power supply device is restricted and the overall device size enlarges
Solution Approach 1:
The electromagnetic shielding function is extracted from the power supply device itself and transferred to the rear bulkhead. The metal casing that would normally cover the battery is removed, and instead the bulkhead is equipped with an electromagnetic wave shield plate that performs the shielding function externally.
Solution Approach 2:
The rear bulkhead acts as an intermediary structure between the power supply device and the cabin. It provides electromagnetic shielding through the shield plate while allowing the power supply device to maintain its original compact size without requiring an integrated metal casing.
2Strength
If the power supply device is positioned in the front area of the rear trunk to secure crush stroke, then collision safety is improved, but electromagnetic waves may directly reach the cabin through bulkhead openings
Solution Approach 1:
The rear bulkhead is designed with different functional zones: the electromagnetic wave shield plate covers the area facing the power supply device to block electromagnetic waves, while the load-through hatch provides structural strength for crash protection. Each region has specialized properties tailored to its specific function.
Solution Approach 2:
The bulkhead is segmented into distinct functional components: the framework reinforcement plate for structural integrity, the electromagnetic wave shield plate for radiation blocking, and the load-through hatch for crash energy management. This segmentation allows each component to optimize its specific function without compromising others.
3Strength
If the rear bulkhead is reinforced to prevent deformation, then structural strength is improved, but the bulkhead thickness increases
Solution Approach 1:
The bulkhead reinforcement system uses composite construction combining the framework reinforcement plate with the electromagnetic wave shield plate. This composite structure achieves enhanced strength and stiffness without requiring a single thick bulkhead, as the distributed reinforcement provides structural integrity while maintaining overall thinness.
Solution Approach 2:
Instead of increasing thickness in the vertical dimension, the reinforcement is distributed across the surface area of the bulkhead through the framework plate and shield plate assembly. This two-dimensional distribution of reinforcement provides structural strength without compromising the compact thickness of the bulkhead.
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 effectively prevents electromagnetic interference from reaching the cabin, reduces the bulkhead's weight and torsional deformation, and allows for easier maintenance of the power supply device while ensuring a longer crush stroke during collisions.
Implementation Method 1
the entire power supply device is required to be electromagnetically shielded with a metal casing
Implementation Method 2
an electromagnetic wave shield unit that is positioned to cover a front surface of the power supply device
Implementation Method 3
a framework reinforcement unit that is fixed to a rectangular framework portion and that reinforces the rectangular framework portion cornerwise
Data Source
AI summary
A structure for mounting a power supply device in a vehicle includes: a rear bulkhead that separates a cabin and a rear trunk; and a power supply device that is disposed in the rear trunk while opposing the rear bulkhead and that has upper, right, left and rear surfaces covered by a metal cover.