Multilayer Battery Shielding Assembly for Low-Frequency EMI
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Solution Overview
Problem
Conventional electromagnetic shielding films struggle to achieve effective shielding for extremely low frequency electromagnetic waves (e.g., less than 100 kilohertz) due to limited shielding effectiveness and increased hardness from alloy plating, making them difficult to process and adhere.
Innovation Solution
The development of electromagnetic energy mitigation assemblies comprising a multilayer structure with first and second electrically conductive layers, permalloy layers, and an electromagnetic noise suppression layer, which enhances shielding effectiveness and maintains softness for easier processing and adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electromagnetic shielding films use alloy plating to improve shielding effectiveness, then shielding performance improves, but the film becomes harder and more difficult to process and adhere
Solution Approach 1:
The patent uses a composite structure combining permalloy layers (for magnetic shielding at low frequencies) with copper or aluminum conductive layers (for electrical shielding). This composite material approach achieves effective shielding across both extremely low frequency and radio frequency ranges while maintaining processability, as the softer copper or aluminum layers facilitate processing and adhesion despite the presence of alloy plating.
2Reliability
If conventional electromagnetic shielding films increase alloy plating thickness to improve shielding, then shielding effectiveness improves, but the film becomes harder and more difficult to process and adhere
Solution Approach 1:
The patent employs a multi-layer composite structure where permalloy layers provide magnetic shielding functionality with optimized thickness for extremely low frequency waves, while copper or aluminum layers provide electrical conductivity and shielding for radio frequencies. The softer copper or aluminum layers act as a matrix that facilitates processing and adhesion, allowing the alloy plating to be effective without compromising manufacturability.
Solution Approach 2:
The patent optimizes the thickness parameters of each layer to achieve the desired shielding effectiveness. The permalloy layers are configured with specific thicknesses (e.g., 0.5-5 micrometers) to provide adequate magnetic shielding, while the copper or aluminum layers are sized to ensure processability and adhesion. This parameter optimization allows effective shielding without excessive alloy thickness that would hinder manufacturing.
3Reliability
If conventional electromagnetic shielding films use thicker material to achieve better shielding, then shielding effectiveness improves, but the film loses softness and becomes difficult to process and adhere
Solution Approach 1:
The patent creates a composite structure where the softer copper or aluminum layers serve as a flexible matrix that maintains the overall softness and pliability of the shielding film. The permalloy layers are incorporated as thinner functional layers within this soft matrix, providing the necessary magnetic shielding without compromising the film's flexibility and ease of handling.
Solution Approach 2:
The patent applies different material properties to different parts of the shielding film. The copper or aluminum layers provide the soft, pliable characteristics needed for ease of handling and processing, while the permalloy layers are strategically positioned and sized to provide localized magnetic shielding functionality. This local differentiation of material properties allows the film to be both soft and effective.
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 proposed solution achieves a shielding effectiveness greater than 20 decibels at frequencies from 10 kilohertz to 30 kilohertz, with a prototype showing at least 38 decibels at 30 kilohertz, while maintaining a soft and pliable structure for practical application.
Implementation Method 1
To shield interference from an external electromagnetic wave, it is common practice to attach an electromagnetic shielding film on electronic equipment
Implementation Method 2
First and second permalloy layers are along respective first and second opposite sides of the first electrically conductive layer. Third and fourth permalloy layers are along respective third and fourth opposite sides of the second electrically conductive layer
Data Source
AI summary
This application discloses electromagnetic energy mitigation assemblies and automotive vehicle components comprising the electromagnetic energy mitigation assemblies. An electromagnetic energy mitigation assembly includes a first electrically conductive layer and a second electrically conductive layer. First and second permalloy layers are along respective first and second opposite sides of the first electrically conductive layer. Third and fourth permalloy layers are along respective third and fourth opposite sides of the second electrically conductive layer. An electromagnetic noise suppression layer is sandwiched between the second and third permalloy layers. An automotive vehicle component includes an electromagnetic energy mitigation assembly configured to be positioned relative to one or more batteries of an automotive vehicle for providing electromagnetic shielding for the one or more batteries. The electromagnetic energy mitigation assembly includes a first electrically conductive layer. First and second permalloy layers are along respective first and second opposite sides of the first electrically conductive layer.