Carbon Nanotube Polymer Composition for EMI Shielding
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Solution Overview
Problem
Current polymer compositions that aim for electrical conductivity often compromise on mechanical and thermal properties, making them unsuitable for high-performance applications in electronic devices such as radar devices and camera modules.
Innovation Solution
A polymer composition incorporating carbon nanostructures dispersed within a thermoplastic polymer matrix, featuring carbon nanotubes arranged in a web-like morphology, which provides both electrical conductivity and maintaining excellent mechanical and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conductive fillers (metal powders, carbon black) are added to achieve electrical conductivity, then electrical conductivity is improved, but mechanical strength and thermal stability deteriorate
Solution Approach 1:
The patent changes the dimensional parameter of the conductive filler from conventional scales to nanoscale (1-100 nm), specifically using carbon nanotubes with diameters of 1-50 nm. This parameter change enables achieving electrical conductivity at much lower filler concentrations (0.1-5 wt%) compared to conventional fillers, thereby maintaining mechanical strength while achieving the desired electrical conductivity for EMI shielding and electrostatic discharge protection
Solution Approach 2:
The patent creates a composite material system combining high-performance thermoplastic polymers (such as PEEK, PPS, PES) with carbon nanotube fillers. This composite approach leverages the excellent mechanical and thermal properties of the polymer matrix while the nanoscale carbon nanotubes provide electrical conductivity, achieving a synergistic effect where both mechanical strength and electrical conductivity are optimized simultaneously
2Reliability
If high filler content is used to achieve desired electrical conductivity, then electrical conductivity is improved, but processing difficulty and manufacturing complexity increase
Solution Approach 1:
The patent reduces the filler concentration parameter from conventional high levels (20-50 wt%) to low nanoscale filler levels (0.1-5 wt%). This parameter change dramatically improves processability and manufacturing ease, as the polymer matrix maintains its original flow characteristics and can be processed using conventional techniques without requiring specialized equipment or complex processing parameters
Solution Approach 2:
The patent utilizes the high aspect ratio and localized conductive network formation capability of carbon nanotubes. The nanotubes form conductive pathways through localized percolation networks rather than requiring uniform distribution throughout the entire matrix. This local quality approach enables achieving electrical conductivity with minimal filler content, simplifying manufacturing while maintaining electrical performance
3Reliability
If conventional conductive materials are used, then electrical conductivity is achieved, but thermal stability and deflection temperature deteriorate
Solution Approach 1:
The patent selects high-performance thermoplastic polymers with inherently high thermal stability (deflection temperatures above 100°C, melting points above 200°C) as the matrix material. Examples include PEEK (deflection temperature ~260°C), PPS (~180°C), and PES (~217°C). When combined with thermally stable carbon nanotube fillers, the composite maintains the matrix polymer's thermal properties while adding electrical conductivity, thus achieving both thermal stability and electrical functionality
Solution Approach 2:
The patent changes the thermal stability parameter by selecting polymer matrices with high glass transition and melting temperatures. The use of aromatic polyesters, polyamides, and polyethers with rigid molecular structures ensures that the composite material maintains dimensional stability and mechanical properties at elevated temperatures, making it suitable for high-temperature processing and application environments
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 composition achieves effective electromagnetic interference (EMI) shielding, electrostatic discharge protection, and retains superior mechanical and thermal properties, including high tensile strength, flexural modulus, and thermal conductivity, suitable for a wide range of electronic device applications.
Implementation Method 1
The carbon nanostructures include carbon nanotubes that are arranged in a network having a web-like morphology
Implementation Method 2
it is often desirable to employ a polymer material in the radar device that has a sufficient degree of electrical conductivity such that it can provide EMI shielding
Implementation Method 3
it is often desirable to employ a polymer material in the camera module that has a sufficient degree of electrical conductivity such that it can provide electrostatic discharge
Data Source
AI summary
A polymer composition comprising carbon nanostructures dispersed within a polymer matrix that includes a thermoplastic polymer having a deflection temperature under load of about 40° C. or more as determined in accordance with ISO 75:2013 at a load of 1.8 MPa and a melting temperature of about 140° C. or more is provided. The carbon nanostructures include carbon nanotubes that are arranged in a network having a web-like morphology and optionally disposed on a substrate.