Composite Shield Assembly for Low-Loss EMI Protection
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Solution Overview
Problem
Conventional shielding layers for high-power electrical components experience large eddy currents leading to thermal loads and reduced performance, adding complexity, weight, and cost.
Innovation Solution
A shield assembly with a magnetic shield layer containing magnetic powder suspended in resin, combined with an electrically-conductive layer, to reduce induced currents and thermal loads, while maintaining effective EMI shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional shielding layers are used for high-power electrical components, then EMI shielding is provided, but large eddy currents are induced causing thermal loads and reduced performance
Solution Approach 1:
The patent applies composite materials by combining magnetic particles (such as ferrite or iron oxide) suspended in an electrically insulating matrix material to create a shielding layer that provides both EMI shielding and reduced eddy current losses. The composite structure allows magnetic flux guidance while the insulating matrix breaks eddy current paths, simultaneously achieving shielding performance and energy efficiency.
Solution Approach 2:
The patent implements local quality by creating a non-uniform distribution of magnetic particles within the shielding layer, concentrating magnetic properties where needed for EMI shielding while maintaining regions with lower conductivity to minimize eddy currents. This localized variation in material properties optimizes both shielding effectiveness and loss reduction.
2Object-affected harmful factors
If conventional shielding layers are used for high-power electrical components, then EMI shielding is provided, but thermal loads increase reducing component performance
Solution Approach 1:
The composite material structure with electrically insulating matrix and magnetic particle dispersion provides thermal management benefits by reducing eddy current heating while maintaining EMI shielding. The insulating matrix prevents excessive heat generation from eddy currents, and the magnetic particles provide shielding, achieving both EMI protection and thermal load reduction simultaneously.
3Object-affected harmful factors
If conventional shielding materials are used, then shielding performance is achieved, but weight and material density increase
Solution Approach 1:
The patent uses composite materials consisting of lightweight magnetic particles (such as ferrite or iron oxide) dispersed in an electrically insulating matrix, replacing traditional heavy metallic shielding materials. This composite approach maintains EMI shielding performance through magnetic flux guidance while significantly reducing the density and weight of the shielding layer.
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 combination of magnetic and electrically-conductive layers provides high shielding performance with low losses, improving current density and efficiency, and reducing material density and weight.
Implementation Method 1
A first shield layer may be disposed within the interior and include magnetic particles suspended in a resin
Implementation Method 2
Conductive components of such systems including wiring, cabling, windings, or the like can experience electromagnetic interference or losses during operation
Data Source
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AI summary
An electrical component (100) and shield assembly can include a set of conductors (120), with the shield assembly having a body (131) at least partially encircling the set of conductors (120). The shield assembly can include a first shield layer (150) radially spaced from a second shield layer (170). The first shield layer (150) can include a magnetic material. The second shield layer (170) can an electrically-conductive material.