Self-Wrap Shield Tube Using CCA Braid for EMI

Solution Overview

Problem

Existing electromagnetic wave shielding solutions for vehicle electrical components are inadequate in terms of workability, weight, and cost, while failing to provide sufficient shielding performance, especially with the increasing complexity of vehicle electronics and stringent EMI regulations.

Innovation Solution

A self-wrap electromagnetic wave shield tube featuring a braid member formed by braiding copper-clad aluminum (CCA) wire bundles and polyolefin-based shrinkage members, which are thermally contracted into a cylindrical shape with overlapping parts, offering improved workability and effective electromagnetic wave shielding with a copper volume fraction of 10 vol % to 25 vol % and a shielding factor of 50 dB or more.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a heat-shrinkable tube is used for electromagnetic wave shielding, then the shielding can be applied after cable connection, but the tube is formed of shrinkable resin or carbon fiber material which cannot sufficiently shield electromagnetic waves

Engineering Contradiction:

Improveworkability of cable connection or cable shielding workVSAvoidelectromagnetic wave shielding performance

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent uses copper-clad aluminum (CCA) wire bundles as the braid member, combining copper's excellent electromagnetic wave shielding properties with aluminum's light weight. This composite material structure achieves both sufficient shielding performance (50 dB or more) and reduced weight compared to traditional copper shielding tubes

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent specifies a copper volume fraction of 10 vol % to 25 vol % in the CCA material to optimize the balance between shielding performance and weight. This parameter optimization ensures adequate electromagnetic wave shielding while minimizing weight and cost

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If a traditional copper shielding tube is used, then sufficient electromagnetic wave shielding is achieved, but the weight and cost increase

Engineering Contradiction:

Improveelectromagnetic wave shielding performanceVSAvoidweight of shielding tube

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent uses copper-clad aluminum (CCA) wire bundles as the braid member, combining copper's excellent electromagnetic wave shielding properties with aluminum's light weight. This composite material structure achieves both sufficient shielding performance (50 dB or more) and reduced weight compared to traditional copper shielding tubes

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent specifies a copper volume fraction of 10 vol % to 25 vol % in the CCA material to optimize the balance between shielding performance and weight. This parameter optimization ensures adequate electromagnetic wave shielding while minimizing weight and cost

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If more copper is used in CCA material to improve shielding, then shielding factor increases, but cost and weight increase

Engineering Contradiction:

Improveshielding factorVSAvoidcopper volume fraction

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent specifies a copper volume fraction of 10 vol % to 25 vol % in the CCA material to optimize the balance between shielding performance and weight. This parameter optimization ensures adequate electromagnetic wave shielding while minimizing weight and cost

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses copper-clad aluminum (CCA) wire bundles as the braid member, combining copper's excellent electromagnetic wave shielding properties with aluminum's light weight. This composite material structure achieves both sufficient shielding performance (50 dB or more) and reduced weight compared to traditional copper shielding tubes

Inventive Principle:

Principle #40Composite materials

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 enhances workability and reduces weight and costs while ensuring sufficient electromagnetic wave shielding performance, meeting stringent EMI regulations by providing a high shielding factor across various signal frequencies.

Implementation Method 1

a plurality of shrinkage members arranged perpendicular to the wire bundles and having a heat shrinkage property, wherein the wire bundles of the braid member are arranged in parallel in a longitudinal direction, the shrinkage members are arranged in a circumferential direction perpendicular to the longitudinal direction, and the braid member is thermally contracted into a cylindrical shape

Methodology Applied

Scientific EffectHeat shrinkage: Thermal Contraction

Implementation Method 2

A main purpose of electromagnetic interference (EMI) shielding is to maintain the inherent performance of a target object by reflecting or absorbing electromagnetic waves generated from the object

Methodology Applied

Scientific EffectElectromagnetic wave reflection and absorption: Absorption (EM radiation)

Data Source

PatentUS11219145B2Self-wrap electromagnetic wave shield tube

Publication Date: 2022.01.04 LS CABLE & SYST LTD

AI summary

The present disclosure relates to a self-wrap electromagnetic wave shield tube and a braid member, which are capable of improving workability of cable connection or cable shielding work and minimizing weight and costs while securing sufficient electromagnetic wave shielding performance in an electrical component space of a vehicle.