CNS-Shielded Wires Using Carbon Nanotube Composites for EMI Shielding
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Solution Overview
Problem
Conductive materials like copper and aluminum used for EMI shielding and lightning protection are heavy, while lighter composites with conductive fibers have poor EMI shielding and lightning protection characteristics due to insulating matrices, leading to a need for alternative materials that can effectively absorb or reflect electromagnetic radiation without increasing weight or complexity.
Innovation Solution
A composite material infused with carbon nanotubes (CNTs) is used, where CNTs are disposed within a matrix material with controlled orientation to enhance EMI shielding effectiveness, capable of absorbing or reflecting electromagnetic radiation across a broad frequency range, and can be integrated into panels or wire shielding layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive materials like copper and aluminum are used for EMI shielding, then EMI shielding effectiveness is improved, but weight increases
Solution Approach 1:
The patent uses carbon nanotube (CNT) infused fiber materials combined with matrix materials to create composite structures that provide EMI shielding effectiveness comparable to traditional metals while significantly reducing weight. The CNT-infused fibers create conductive pathways within the composite material, enabling electromagnetic interference shielding without the heavy weight of copper or aluminum.
2Weight of moving object
If lighter composite materials are used, then weight is reduced, but EMI shielding and lightning protection characteristics deteriorate
Solution Approach 1:
The invention creates lightweight composite materials by infusing carbon nanotubes into fiber materials and combining them with matrix materials. This composite structure provides both the lightweight advantage and the EMI shielding effectiveness, as the CNT-infused fibers establish conductive networks within the otherwise insulating composite material.
Solution Approach 2:
The patent applies CNT infusion specifically to fiber materials within the composite structure, creating localized conductive pathways where needed for EMI shielding and lightning protection, while the rest of the composite maintains its lightweight insulating matrix structure.
3Reliability
If metal fillers or metal coatings are incorporated in composites to improve EMI shielding, then EMI shielding characteristics are improved, but device complexity and weight increase
Solution Approach 1:
The patent integrates carbon nanotubes directly into the fiber material structure during manufacturing, creating an inherently conductive composite material. This eliminates the need for separate metal fillers, coatings, or additional shielding components, thereby reducing overall device complexity while maintaining EMI shielding effectiveness.
Solution Approach 2:
The invention merges the structural fiber material with the EMI shielding function by infusing carbon nanotubes into the fibers. This combination creates a multi-functional material that simultaneously provides structural support and electromagnetic interference shielding, eliminating the need for separate shielding layers or components.
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 CNT-infused composite provides effective EMI shielding with a shielding effectiveness range of 40 dB to 130 dB, allowing for the use of lighter materials with improved EMI shielding and lightning protection characteristics, suitable for various applications including electronic devices and communication systems.
Implementation Method 1
The CNT-infused composite provides effective EMI shielding with a shielding effectiveness range of 40 dB to 130 dB, capable of absorbing electromagnetic (EM) radiation
Implementation Method 2
The composite is capable of absorbing electromagnetic (EM) radiation, reflecting EM radiation, or combinations thereof in a frequency range from between about 0.01 MHz to about 18 GHz
Data Source
AI summary
A shielded wire includes a carbon nanostructure (CNS)-shielding layer including a CNS material in a matrix material, the CNS-shielding layer being monolithic and disposed about a dielectric layer and a conducting wire, wherein the dielectric layer is disposed between the CNS-shielding layer and the conducting wire. An extruded thermoplastic jacket includes a CNS material, the extruded thermoplastic jacket being configured to protect at least one wire. A thermoplastic article includes a CNS-infused fiber material and a flexible thermoplastic.