EMI Shielding Resin Composition for Lightweight Moldable Cables
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Solution Overview
Problem
Conventional metal materials used for electromagnetic wave shielding are heavy, difficult to process, and costly, limiting their application in weight reduction and moldability, especially in the automobile industry, while polymer composite materials with high conductive filler content compromise mechanical properties and moldability.
Innovation Solution
A resin composition comprising 20-80 wt% thermoplastic resin, 1-50 wt% conductive filler (such as carbon fiber, carbon nanotube, or carbon black), and 0.1-30 wt% additive, along with a cable design featuring a conductive polymer layer, offers excellent electromagnetic wave shielding performance, light-weight properties, and mechanical strength equivalent to metal, replacing traditional metal materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal material is used for electromagnetic wave shielding, then shielding efficiency is improved, but weight increases and processing difficulty increases
Solution Approach 1:
The patent uses a composite material consisting of polymer resin and conductive filler (carbon fiber, carbon nanotube, or metal powder) to replace traditional metal shielding materials. This composite structure achieves electromagnetic wave shielding functionality while significantly reducing weight compared to solid metal materials.
Solution Approach 2:
The patent optimizes the content ratio of conductive filler to polymer resin to achieve the desired shielding efficiency while maintaining light weight. By controlling the filler content within specific ranges and using different types of conductive fillers, the shielding performance is adjusted without compromising the weight advantage.
2Reliability
If metal material is used for electromagnetic wave shielding, then shielding efficiency is improved, but ease of manufacture deteriorates
Solution Approach 1:
The polymer-based composite material combines the ease of polymer processing with the shielding functionality of conductive fillers. The composite can be processed using conventional polymer processing techniques such as injection molding, extrusion, and compression molding, making it much easier to manufacture than metal shielding materials.
Solution Approach 2:
By adjusting the polymer resin matrix and processing parameters, the composite material achieves both good processability and adequate shielding efficiency. The polymer matrix provides flexibility in processing while the conductive filler provides shielding functionality.
3Reliability
If conductive filler content is increased to improve shielding efficiency, then shielding performance is improved, but flowability and moldability deteriorate
Solution Approach 1:
The patent optimizes the conductive filler content within specific ranges (1-50 wt% or 10-40 wt%) to achieve the desired shielding efficiency while maintaining adequate flowability and moldability. By controlling the filler content and using appropriate polymer matrices, the composite maintains processability.
Solution Approach 2:
The patent uses different types of conductive fillers (carbon fiber, carbon nanotube, carbon black, metal powder) with different properties to achieve shielding efficiency while minimizing the negative impact on flowability. The selection of filler type and size distribution allows optimization of both shielding and processing properties.
4Reliability
If conductive filler content is increased to improve shielding efficiency, then shielding performance is improved, but mechanical properties deteriorate
Solution Approach 1:
The patent optimizes the conductive filler content within specific ranges to achieve adequate shielding efficiency while maintaining mechanical properties. By controlling the filler content and selecting appropriate polymer matrices, the composite maintains both shielding performance and mechanical strength.
Solution Approach 2:
The polymer matrix provides mechanical strength and structural integrity while the conductive filler provides shielding functionality. This composite structure allows the polymer to carry the mechanical load while the filler provides electromagnetic wave shielding, achieving both requirements simultaneously.
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 resin composition and cable design achieve improved electromagnetic wave shielding, mechanical strength, and productivity while reducing weight, addressing the limitations of metal materials and maintaining high shielding efficiency and moldability.
Implementation Method 1
a conductive filler which is one selected from the group consisting of carbon fiber, carbon nanotube, carbon black, and a mixture of two or more among the above components
Implementation Method 2
Metal is used as various materials for shielding electromagnetic waves because it has high electrical conductivity and excellent electromagnetic wave reflection properties
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
An embodiment resin composition for shielding electromagnetic waves, based on a total weight of the resin composition, includes 20 to 80 wt% of thermoplastic resin, 1 to 50 wt% of a conductive filler, and 0.1 to 30 wt% of an additive. The conductive filler includes carbon fiber, carbon nanotube, carbon black, or combinations thereof