Electromagnetic Shielding Material Using Magnetic Alignment

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Solution Overview

Problem

Existing electromagnetic shielding materials for aerial and aerospace vehicles are heavy, reducing fuel efficiency and flight range due to their dense metal compositions, necessitating the development of lighter yet effective shielding solutions.

Innovation Solution

A method involving the application of a magnetic field to a precursor material with ferromagnetic particles embedded in a matrix material, aligning the particles and then forcing them through a filter to concentrate them, followed by curing the matrix to form a lightweight electromagnetic shielding material with aligned ferromagnetic particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If dense continuous metal sheets or mesh cages are used for EMI shielding enclosures, then electromagnetic shielding effectiveness is improved, but weight increases

Engineering Contradiction:

Improveelectromagnetic shielding effectivenessVSAvoidenclosure weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent uses composite materials consisting of ferromagnetic particles (20-70% by mass) embedded in a non-conductive matrix material. This composite structure provides EMI shielding through the magnetic properties of the ferromagnetic particles while the non-conductive matrix reduces overall density and weight compared to solid metal enclosures.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies magnetic field treatment locally to align ferromagnetic particles in specific orientations within the composite material. This localized alignment enhances shielding effectiveness in critical directions without requiring uniform high-density metal throughout the entire enclosure structure.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If ferromagnetic particles are aligned with magnetic field, then electromagnetic shielding effectiveness is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveelectromagnetic shielding effectivenessVSAvoidmanufacturing process complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent applies magnetic field treatment during the manufacturing process to pre-align ferromagnetic particles before the matrix material fully cures. This preliminary alignment action ensures optimal particle orientation is achieved during fabrication, simplifying subsequent processing steps and ensuring consistent shielding performance.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical alignment systems with a magnetic field application system. Instead of using mechanical devices to physically position and orient ferromagnetic particles, a magnetic field is applied to induce alignment, significantly simplifying the manufacturing apparatus and process while achieving the same shielding effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution results in a lighter yet effective electromagnetic shielding material that can block or absorb electromagnetic radiation, improving the performance of avionic and aerospace equipment by reducing electromagnetic interference without compromising fuel efficiency.

Implementation Method 1

applying a magnetic field to a precursor material that comprises first ferromagnetic particles embedded within a first portion of a matrix material and second ferromagnetic particles embedded within a second portion of the matrix material, thereby causing the first ferromagnetic particles and the second ferromagnetic particles to move such that longitudinal axes of the first ferromagnetic particles and the second ferromagnetic particles become more aligned with the magnetic field

Methodology Applied

Scientific EffectMagnetic field alignment: Magnetic Field

Implementation Method 2

thereafter forcing the first portion of the matrix material through a filter, thereby moving the first ferromagnetic particles from the first portion of the matrix material into the second portion of the matrix material

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 3

curing the second portion of the matrix material to form the electromagnetic shielding material

Methodology Applied

Scientific EffectCuring: Phase Change

Data Source

PatentUS10932399B1Electromagnetic shielding material and methods of formation

Publication Date: 2021.02.23 THE BOEING CO

AI summary

Examples include a method of forming an electromagnetic shielding material, the method including: applying a magnetic field to a precursor material that includes first ferromagnetic particles embedded within a first portion of a matrix material and second ferromagnetic particles embedded within a second portion of the matrix material, thereby causing the first ferromagnetic particles and the second ferromagnetic particles to move such that longitudinal axes of the first ferromagnetic particles and the second ferromagnetic particles become more aligned with the magnetic field; thereafter forcing the first portion of the matrix material through a filter, thereby moving the first ferromagnetic particles from the first portion of the matrix material into the second portion of the matrix material; and curing the second portion of the matrix material to form the electromagnetic shielding material. Additional examples include an electromagnetic shielding material and an apparatus for forming an electromagnetic shielding material.