Core-Sheath Conductive Yarn for Electromagnetic Shielding
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Solution Overview
Problem
Conventional braided, woven, or knitted electromagnetic shielding materials often compromise on mechanical or chemical properties to achieve effective electrical conductivity, leading to suboptimal performance in shielding effectiveness, corrosion resistance, and durability.
Innovation Solution
The development of electrically conductive yarns with a core and sheath structure, where the core material exceeds the sheath in electrical conductivity, and the sheath exceeds the core in tensile strength or corrosion resistance, forming a braided, woven, or knitted mesh for improved shielding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional braided, woven, or knitted electromagnetic shielding materials use single metal filaments or simple core-sheath structures, then electrical conductivity can be achieved, but mechanical strength and corrosion resistance are compromised
Solution Approach 1:
The patent employs composite filaments consisting of a copper core surrounded by a stainless steel sheath. The copper core provides high electrical conductivity for effective electromagnetic shielding, while the stainless steel sheath contributes superior tensile strength and corrosion resistance. This composite structure resolves the contradiction by combining materials with complementary properties, allowing the shielding material to simultaneously achieve high reliability and mechanical strength.
Solution Approach 2:
The invention applies different material properties to different parts of the filament structure. The inner core region is optimized for electrical conductivity using copper, while the outer sheath region is optimized for mechanical strength and corrosion resistance using stainless steel. This local differentiation of material quality allows each region to fulfill its specific function, resolving the contradiction between shielding effectiveness and mechanical strength.
2Strength
If conventional shielding materials use thicker filaments to improve mechanical strength, then tensile strength increases, but the mesh becomes thicker and heavier
Solution Approach 1:
The patent employs composite filaments where the stainless steel sheath provides high strength-to-weight ratio, enabling the use of thinner overall filament diameters while maintaining mechanical strength. This allows the mesh to be both strong and lightweight, resolving the contradiction between tensile strength and mesh weight.
Solution Approach 2:
The invention changes the material composition parameters of the filament, using a core-sheath structure with optimized thickness ratios. The stainless steel sheath provides structural strength with minimal thickness, allowing the overall filament diameter to be reduced while maintaining tensile strength, thereby reducing mesh weight.
Data Source
AI summary
An electromagnetic shielding material includes multiple strands of an electrically conductive yarn that are arranged as a braided, knitted, or woven mesh. Each strand of the electrically conductive yarn comprises one or more electrically conductive filaments; each electrically conductive filament comprises a core of a first electrically conductive material surrounded by a sheath of a second electrically conductive material different from the first electrically conductive material. The first electrically conductive material exceeds the second electrically conductive material with respect to electrical conductivity, while the second electrically conductive material exceeds the first electrically conductive material with respect to one or more of tensile strength, corrosion resistance, or one or more other mechanical or chemical properties or characteristics. In many examples, the first electrically conductive material includes copper and the second electrically conductive material includes stainless steel.