High-Voltage Wire Tray Structure for EMI-Shielded Junction Boxes
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Solution Overview
Problem
Electrified vehicles face electromagnetic interference (EMI) issues due to high-voltage power electronics, which affect the functionality of other systems and components, necessitating effective shielding solutions within high-voltage junction boxes.
Innovation Solution
A wire tray with a base and transverse walls is designed to shield power distribution wires from electromagnetic interference generated by circuit board assemblies, using a conductor to provide a ground path for interference and integrating features like wire routing aids and connectors to prevent incorrect assembly and enhance assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire tray with conductor and transverse walls is added to shield power distribution wires from EMI, then electromagnetic compatibility is improved, but device complexity increases
Solution Approach 1:
The wire tray structure is merged with the EMI shielding function by integrating a conductor into the tray base. The tray simultaneously performs wire support, organization, and electromagnetic shielding, eliminating the need for separate shielding components and reducing overall device complexity despite adding EMI protection capability.
Solution Approach 2:
The wire tray is constructed as a composite structure combining an electrically insulative material (molded material) with an embedded conductor. This composite design provides both mechanical support and EMI shielding functionality, resolving the contradiction by achieving electromagnetic compatibility without requiring additional complex shielding structures.
2Manufacturing precision
If multiple transverse walls are added to define separate channels for wire routing, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The wire tray is segmented into multiple channels by transverse walls, with each channel sized to receive specific power distribution wires. This segmentation provides precise routing paths for individual wires, improving assembly precision by guiding wire placement while maintaining a simple integrated tray structure rather than requiring separate routing components.
Solution Approach 2:
The wire tray serves multiple functions simultaneously: it provides structural support for wires, defines precise routing channels through transverse walls, and offers EMI shielding through the embedded conductor. This multi-functionality reduces the need for additional components, offsetting the increased complexity from added walls while improving assembly precision.
3Productivity
If the wire tray integrates conductor and insulative material in a molded structure, then manufacturing efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The conductor is embedded within the insulative material during the molding process itself, performing the shielding structure creation in advance. This preliminary integration eliminates subsequent assembly steps for installing separate shielding components, improving manufacturing efficiency while the molding process inherently provides the necessary precision for conductor placement and tray geometry.
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 shields high-voltage DC power from EMI, reduces assembly time, and integrates features to eliminate components, resulting in cost reduction and improved electromagnetic compatibility.
Implementation Method 1
A conductor is disposed within the base and adapted to connect to a vehicle chassis to provide a ground path for electromagnetic interference generated by the inverter and shield the first and second power distribution wires
Data Source
AI summary
An electronic module is provided with a housing with an inlet to conduct alternating current (AC) power and an outlet to conduct direct current (DC) power to charge a vehicle battery, the housing defining a cavity. A circuit board assembly is supported within the cavity to convert the AC power to DC power. At least two power distribution wires are connected between the circuit board assembly and the outlet. A base is supported by the housing and extends between the at least two power distribution wires and the circuit board assembly to shield the DC power from electromagnetic interference generated by the circuit board assembly. A plurality of walls extend transversely from the base and are spaced apart from each other to define at least two channels, each channel is sized to receive one of the at least two power distribution wires.