Shielded Battery Module Housing for Wireless Monitor Reliability

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Solution Overview

Problem

Conventional power systems with battery monitoring systems face challenges in preventing electromagnetic noise interference and leakage during wireless communication between battery monitors and ECUs.

Innovation Solution

A battery module with assembled batteries, individual detectors, communicators, and a communications monitor, housed in an electromagnetic shielding compartment with a non-electromagnetic shielding portion and an opposing electromagnetic shield to inhibit or suppress electromagnetic noise interference and leakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wireless communication is implemented between battery monitors and ECU, then monitoring capability is improved, but electromagnetic noise interference and leakage occur

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidelectromagnetic noise interference

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

An electromagnetic shielding housing acts as an intermediary barrier between the wireless communication components and the external environment. The housing with its conductive walls and shielding mesh filters electromagnetic noise before it reaches the battery monitors and ECU, while still permitting necessary wireless communication signals to pass through.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates an electromagnetically inert environment inside the housing by using conductive materials and shielding structures. This inert electromagnetic atmosphere protects sensitive monitoring components from external electromagnetic interference while containing internal radio wave leakage.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Reliability

If wireless communication is implemented between battery monitors and ECU, then monitoring capability is improved, but radio wave leakage to external equipment occurs

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidradio wave leakage

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potentially harmful radio wave leakage into a controlled phenomenon by using the shielding housing to redirect and contain electromagnetic emissions. The housing transforms uncontrolled radiation into directed signals that can be managed and filtered, turning a harmful side effect into a controllable parameter.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The electromagnetic shielding housing uses thin conductive shells and shielding mesh that are flexible enough to maintain structural integrity while providing effective electromagnetic containment. These thin film structures block radio wave leakage without significantly increasing the overall size of the battery monitor unit.

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-affected harmful factors

If electromagnetic shielding housing is added, then electromagnetic noise interference is suppressed, but device complexity increases

Engineering Contradiction:

Improveelectromagnetic noise interferenceVSAvoidhousing structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The electromagnetic shielding housing serves multiple functions simultaneously: it provides mechanical protection for internal components, contains electromagnetic radiation, filters external electromagnetic noise, and structurally integrates with the battery monitor housing. This multi-functionality reduces the need for separate shielding components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the electromagnetic shielding function with the existing housing structure of the battery monitor. Instead of adding separate shielding components, the shielding features are integrated into the housing itself, combining structural support and electromagnetic protection into a single unified structure.

Inventive Principle:

Principle #5Merging (Combining)

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 solution effectively inhibits or suppresses electromagnetic noise interference and leakage, ensuring reliable wireless communication between battery monitors and ECUs while preventing external radio wave leakage.

Implementation Method 1

an electromagnetic shield arranged opposite to the non-electromagnetic shielding portion in the electromagnetic shielding housing

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentUS12294065B2Battery module and power system

Publication Date: 2025.05.06 DENSO CORP

AI summary

A power system includes a battery module and a battery ECU. The battery module includes multiple battery stacks. Each of multiple battery stacks includes multiple battery cells, multiple detectors which independently detect physical values of the multiple battery cells, respectively, and multiple individual communicators which wirelessly output detection results of the multiple detectors. Each of the multiple individual communicators communicates a radio signal wirelessly to and from a general monitor. The multiple battery stacks and the general monitor are accommodated in a storage space in a housing having electromagnetic shielding performance. A shield is also accommodated in the storage space while facing a communication hole formed on the housing.