Clad Electromagnetic Shielding Material Metallurgical Bonding
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Solution Overview
Problem
Conventional electromagnetic shielding materials face challenges in achieving effective heat dispersion, structural strength, light weight, and shock-absorbing properties while maintaining electromagnetic shielding effectiveness, particularly due to high interface resistance and inadequate bonding between layers.
Innovation Solution
A clad type electromagnetic shielding material is manufactured by mechanically and metallurgically bonding a flexible electrically conductive metallic layer with a magnetically conductive metallic layer using a rolling process, and then adhering a shock-absorbing insulation layer with a binder, allowing for controlled rolling and heating to achieve uniform bonding strength and stable thickness, thereby optimizing electromagnetic shielding and incorporating additional properties like heat dispersion and structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding is used to connect ferromagnetic material layer with substrate, then electromagnetic shielding effectiveness is improved, but heat dispersion deteriorates due to high interface resistance
Solution Approach 1:
The patent replaces adhesive bonding with metallurgical bonding through a rolling process. The rolling process applies mechanical pressure and heat to create a metallurgical bond between the ferromagnetic material layer and the electrically conductive layer, eliminating the need for adhesives and reducing interface resistance for heat transfer.
Solution Approach 2:
The patent changes the bonding parameters from chemical adhesive bonding to physical metallurgical bonding through controlled rolling pressure and temperature. This parameter change achieves both electromagnetic shielding effectiveness and improved heat dispersion by creating a low-resistance thermal interface.
2Reliability
If multiple layers are bonded together by adhesive connection, then electromagnetic shielding effectiveness is improved, but structural strength deteriorates due to weak bonding regions
Solution Approach 1:
The patent replaces weak adhesive bonding with strong metallurgical bonding through rolling. The rolling process creates a permanent metallurgical connection between layers that is mechanically stronger than adhesive bonds, while maintaining the electromagnetic shielding functionality.
3Reliability
If conventional multi-layer structure is used, then electromagnetic shielding effectiveness is improved, but manufacturing complexity increases due to multiple bonding steps
Solution Approach 1:
The patent merges multiple bonding operations into a single rolling process. Instead of separately applying adhesives and performing multiple bonding steps, the rolling process simultaneously bonds all layers together in one operation, simplifying the manufacturing process.
Solution Approach 2:
The rolling process serves multiple functions simultaneously: it bonds the layers together metallurgically, controls the thickness of each layer, and provides heat treatment to the materials. This multi-functionality reduces manufacturing complexity compared to conventional multi-step processes.
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 achieves simultaneous electromagnetic shielding, heat dispersion, structural strength, and shock-absorbing properties with low interface resistance, utilizing copper for heat dispersion, aluminum for light weight, and a high polymer layer for insulation, while being a green environmental process.
Implementation Method 1
a flexible electrically conductive metallic layer is mechanically and metallurgically bonded with a magnetically conductive metallic layer by a rolling technology
Implementation Method 2
they are bound (i.e., adhered) with a shock-absorbing insulation layer
Implementation Method 3
utilizing copper for heat dispersion
Implementation Method 4
after the clad type rolling process, the method for manufacturing the clad type electromagnetic shielding material further includes a reprocessing temperature control step of: annealing the clad plate in an annealing process
Data Source
AI summary
A method for manufacturing a clad type electromagnetic shielding material includes step as follows: a first electrically conductive metallic layer, a magnetically conductive metallic layer, a second electrically conductive metallic layer and a shock-absorbing insulation layer, which are stacked in order, are one-time continuously rolled by a clad type rolling process, so as to finish a clad plate applied to an electromagnetic shielding field, wherein the surface of the shock-absorbing insulation layer provided with a binder faces the second electrically conductive metallic layer.