Conductive Mesh Transparency for EMI Shielding With Low Diffraction
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Solution Overview
Problem
Current aircraft and armor-grade transparencies are expensive to produce and often have unsatisfactory de-icing, static dissipation, and electromagnetic interference (EMI) shielding capabilities, with complex manufacturing processes that increase costs and risk of defects.
Innovation Solution
A transparency with a conductive mesh of intersecting electrically conductive lines, formed using methods like inkjet printing or aerosol jet printing, which provides EMI shielding, de-icing, and static dissipation while reducing optical distortion and being more economical to produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electroplating and vacuum deposition processes are used to create conductive transparencies, then EMI shielding and static dissipation capabilities are achieved, but manufacturing cost increases and production complexity increases
Solution Approach 1:
The patent extracts the essential function of providing EMI shielding and static dissipation from complex multi-step electroplating and vacuum deposition processes, isolating it to a simpler screen printing process using conductive ink formulations, thereby maintaining reliability while reducing manufacturing complexity
Solution Approach 2:
The patent employs disposable screen printing masks and simple conductive ink formulations that can be applied without expensive vacuum chambers or electroplating equipment, replacing costly durable infrastructure with simpler, more economical materials and processes
2Reliability
If traditional electroplating and vacuum deposition processes are used to create conductive transparencies, then EMI shielding and static dissipation capabilities are achieved, but manufacturing expense increases
Solution Approach 1:
The patent replaces complex mechanical and chemical systems (electroplating baths, vacuum deposition chambers, multiple coating layers) with a simpler printing-based application method using conductive inks, significantly reducing equipment costs and manufacturing expenses while maintaining static dissipation capability
Solution Approach 2:
The patent changes the fundamental parameters of the conductive layer formation process from electrochemical deposition or physical vapor deposition to solution-based printing, altering material application, drying, and curing parameters to achieve comparable performance at lower cost
3Reliability
If wider electrically conductive lines are used in the transparency, then EMI shielding capability is improved, but optical distortion and diffraction increase
Solution Approach 1:
The patent optimizes the width parameter of conductive lines to a specific range that balances EMI shielding effectiveness with optical clarity, using screen printing techniques to achieve consistent line widths that provide adequate conductivity while minimizing diffraction and visual distortion
Solution Approach 2:
The patent uses composite conductive ink formulations containing metal particles, ceramic particles, or polymer matrices that provide adequate electrical conductivity with thinner line widths, thereby maintaining EMI shielding capability while reducing optical distortion and diffraction effects
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 conductive mesh transparency offers effective EMI shielding, de-icing, and static dissipation, while being more cost-effective and durable, with improved optical clarity and reduced manufacturing complexity compared to traditional methods.
Implementation Method 1
The buildup of static charge can be prevented or reduced by draining or dissipating the static electricity that can build up on the transparency
Implementation Method 2
EMI shielding can be provided by preventing or reducing the transmission of disruptive electromagnetic radiation (i.e., electromagnetic radiation that interferes with electronic systems) through the transparency
Implementation Method 3
at least one of the electrically conductive lines having a width of no more than 50 μm to reduce distraction resulting from optical diffraction of light transmitted through or reflected by the transparency
Data Source
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AI summary
A transparency includes a transparent substrate and a plurality of electrically conductive lines on the transparent substrate, at least one of the electrically conductive lines intersecting at least one other electrically conductive line, and at least one of the electrically conductive lines having a width of no more than 50 µm to reduce distraction resulting from optical diffraction of light transmitted through or reflected by the transparency as compared to a transparency comprising electrically conductive lines having a width greater than 50 µm. A coated substrate includes: a substrate; a dielectric layer on the substrate; and a sensor including a conductive layer on the dielectric layer, where at least one layer selected from the dielectric layer and the conductive layer is formed by at least one method selected from lithography, inkjet printing, and aerosol jet printing.