Composite Shielding Layer for Lightweight High-Voltage Wire
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Solution Overview
Problem
Conventional high-voltage cables with metal braided wires for electromagnetic shielding are heavy, contributing to increased vehicle weight and have low productivity due to slow production speeds, while requiring both flexibility, heat resistance, and insulation.
Innovation Solution
A high-voltage shielded wire using an electromagnetic shielding composite resin composition comprising a thermoplastic resin, metal-coated carbon fibers, carbon black, and carbon nanotubes, which provides excellent shielding performance and is lighter than conventional metal braided wires, allowing for a faster extrusion-based production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If metal braided wires are used for electromagnetic shielding in high-voltage cables, then shielding performance is improved, but weight increases
Solution Approach 1:
The patent uses a composite resin composition containing carbon fibers, metal-coated carbon fibers, and carbon nanotubes embedded in a polymer matrix to replace traditional metal braided shielding layers. This composite material provides effective electromagnetic shielding through the conductive network formed by carbon-based materials while maintaining low weight, directly resolving the contradiction between shielding performance and cable weight
Solution Approach 2:
The patent changes the material parameters from dense metal braids to a composite resin system with specific carbon content (5-50 parts by weight based on 100 parts thermoplastic resin). This parameter change enables achieving adequate shielding efficiency (20-30 dB) with significantly reduced weight compared to conventional metal shielding structures
2Object-affected harmful factors
If metal braided wires are used for electromagnetic shielding, then shielding performance is improved, but production speed decreases
Solution Approach 1:
The patent replaces the mechanical braiding process with a polymer extrusion process. The composite resin composition is extruded directly onto the insulation layer in a continuous manner, eliminating the complex mechanical operations of metal wire braiding. This substitution dramatically increases production speed while maintaining shielding effectiveness through the embedded conductive carbon network
3Weight of moving object
If composite resin composition with carbon fibers is used for shielding, then weight is reduced, but shielding efficiency may be compromised
Solution Approach 1:
The patent creates a synergistic composite system where carbon fibers provide structural framework and conductivity, metal-coated carbon fibers enhance surface conductivity and shielding reflection, and carbon nanotubes fill gaps to create a dense conductive network. This multi-component composite achieves both low weight and high shielding efficiency (20-30 dB) simultaneously
Solution Approach 2:
The patent applies different carbon-based materials at different locations and scales within the shielding layer: carbon fibers provide bulk conductivity, metal-coated carbon fibers provide surface-level shielding, and carbon nanotubes provide fine-scale gap filling. This local differentiation of material properties ensures comprehensive electromagnetic shielding while maintaining overall lightness
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 composite resin composition achieves a 20 to 30% weight reduction and significantly improves electromagnetic shielding efficiency, with production speeds up to 17 times faster than conventional metal braiding methods, while maintaining essential cable functions.
Implementation Method 1
an electromagnetic shielding layer surrounding the insulation layer and employing an electromagnetic shielding composite resin composition... the electromagnetic shielding composite resin composition contains a thermoplastic resin, a metal-coated carbon fiber, carbon black, and a carbon nanofiber
Data Source
AI summary
The present invention relates to an electromagnetic shielding composite resin composition and a high-voltage shielded wire comprising the same. More particularly, the present invention relates to a high-voltage shielded wire comprising: a core composed of a conductive material; an insulation layer enveloping the core; an electromagnetic shielding layer surrounding the insulation layer and employing an electromagnetic shielding composite resin composition; and a coating layer covering the electromagnetic shielding layer and composed of an insulation material, wherein the electromagnetic shielding composite resin composition contains a thermoplastic resin, a metal-coated carbon fiber, carbon black, and a carbon nanofiber.