Braided Shield Composite Structure for Lightweight EMI Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing braided shields for electrical wires face degradation in shield characteristics due to high braiding ratios, which increase costs and weight, and disruption from skewed overlapping, making it challenging to achieve optimal shield performance while maintaining a lightweight construction.
Innovation Solution
A braided shield with a cylindrical structure formed by interweaving strip-shaped non-conductor and conductor members, where the conductor member is shorter than the non-conductor film, arranged in a specific ratio to maintain a 75% braiding ratio, ensuring optimal shield characteristics and reducing conductor usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the braiding ratio is raised by increasing the number of wire filaments or reducing gaps between filament bundles, then the shield characteristics improve, but the weight and cost of the shielded electrical wire increase
Solution Approach 1:
The patent changes the fundamental parameter of the shield structure from traditional wire filaments to a composite structure consisting of a non-conductor film with a conductor member attached. This parameter change allows achieving high shield characteristics (equivalent to 100% braiding ratio) while reducing the actual amount of conductor material used, thereby reducing weight and cost without sacrificing shielding performance
Solution Approach 2:
The patent employs a composite structure combining a non-conductor film (such as PET film) with a conductor member (such as aluminum foil or copper foil). This composite approach allows the non-conductor portion to occupy space that would traditionally require conductor material, reducing overall conductor usage and weight while maintaining effective electromagnetic shielding through the conductor member's presence
2Reliability
If the braiding ratio is raised to account for braiding disruption, then shield characteristics are maintained, but it becomes impossible to braid a pattern with superior shield characteristics
Solution Approach 1:
The patent fundamentally changes the braiding parameter from using flexible wire filaments to using rigid or semi-rigid composite units (non-conductor film with attached conductor member). This parameter change eliminates the problem of braiding disruption and skewed overlapping that plagues traditional wire filament approaches, allowing consistent achievement of optimal braiding patterns with superior shield characteristics
Solution Approach 2:
The shield structure is segmented into discrete composite units (non-conductor film segments with conductor members) that are braided together. This segmentation allows for more controlled and consistent braiding behavior compared to continuous wire filaments, reducing braiding disruption and enabling more reliable production of high-performance shield patterns
Data Source
AI summary
A braided shield includes at least one electrical wire; and a plurality of shield members that covers an outer circumferential surface of the electrical wire and is formed by interweaving into a cylindrical shape. The shield members each include a strip-shaped non-conductor film and a strip-shaped conductor member that is shorter than a width of the non-conductor film in a width direction. In a planar view of the shield member, the conductor member is stacked on the non-conductor film along the longitudinal direction thereof such that the non-conductor area and the conductor area are formed separately along the width direction of the non-conductor film.