Conductive Foil Shielding for Non-Conductive Housing
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Solution Overview
Problem
Existing methods for shielding electrical devices, such as high-voltage storage devices, from electromagnetic radiation using non-conductive materials like plastics are complex, costly, and often result in poor shielding properties and mechanical property degradation, especially when relying on manual application of conductive paints or inserts.
Innovation Solution
A method involving the use of electrically and magnetically conductive foils shaped to match the housing's geometry, which are attached via heat sealing, gluing, or screwing, providing a reliable and efficient shielding solution by integrating the foil with the non-conductive housing material during the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conductive EMC paints are applied to the surface of a non-conductive housing, then shielding against electromagnetic radiation is achieved, but the mechanical properties of the housing are adversely affected and the shielding properties are poor
Solution Approach 1:
The patent uses a composite structure consisting of a non-conductive housing base material combined with a conductive foil layer. This composite approach provides effective electromagnetic shielding while maintaining the mechanical properties of the non-conductive housing, avoiding the degradation caused by conductive paints.
Solution Approach 2:
The patent employs a thin conductive foil that is formed to match the housing geometry and attached to the non-conductive housing. This thin film approach provides effective shielding without adding significant weight or compromising mechanical strength, unlike thick conductive paint applications.
2Object-affected harmful factors
If EMC fabric or conductive fleece is inserted into the non-conductive base material of the housing, then shielding against electromagnetic radiation is achieved, but the processes are very complex and associated with high costs
Solution Approach 1:
The conductive foil is pre-formed to match the housing geometry before attachment, simplifying the overall process. This preliminary shaping eliminates the need for complex insertion processes required for fabric or fleece materials.
Solution Approach 2:
The patent changes the physical state and form of the conductive material from bulky fabric/fleece to a thin, pre-formed foil that can be easily attached to the housing surface, significantly simplifying the manufacturing process.
3Object-affected harmful factors
If additional measures are taken on a non-conductive housing to make it electrically conductive, then shielding against electromagnetic radiation is achieved, but the required mechanical properties of the housing can be adversely affected
Solution Approach 1:
The patent creates a composite structure where a conductive foil is combined with a non-conductive housing, achieving homogeneous conductivity across the housing surface while preserving the mechanical properties of the base material.
4Object-affected harmful factors
If fabric, tiles or EMC paints are applied manually to the housing, then shielding against electromagnetic radiation is achieved, but they are not suitable for large-scale production
Solution Approach 1:
The patent transforms the conductive material into a pre-formed foil with specific geometric parameters that enable automated attachment processes, making the housing suitable for large-scale production unlike manual application methods.
Solution Approach 2:
The conductive foil is pre-formed and prepared before housing assembly, enabling automated attachment processes and significantly improving productivity for large-scale production compared to manual application of paints or fabrics.
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
This approach ensures effective shielding against electromagnetic radiation with improved mechanical properties and reduced weight, offering better damping capabilities compared to traditional methods, while being scalable and suitable for large-scale production.
Implementation Method 1
The film can be attached to the outer or inner wall of the housing, for example by heat sealing, gluing or by screwing.
Implementation Method 2
An electrical device may include electrical equipment and a housing that encloses the electrical equipment for protection. To ensure proper operation of the electrical device, it is necessary for numerous electrical devices that the housing shields the electrical device from electromagnetic radiation.
Data Source
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AI summary
In a method for producing a housing having shielding against electric and/or magnetic radiation, an electrically and/or magnetically conductive foil (10) and a housing (20) made of an electrically and/or magnetically non-conductive material and having an outer and an inner wall (21, 22) are provided. The foil (10) is shaped such that a shape of the foil (10) corresponds to a shape of the outer or inner wall (21, 22) of the housing (20). The foil (10) is arranged on the inner or outer wall (21, 22) of the housing (20).