Fe-Cu Alloy Foil for High-Frequency EMI Shielding
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Solution Overview
Problem
Conventional electromagnetic wave shielding techniques for cables, such as using copper tape or aluminum tape, are inadequate as they generate heat, increase manufacturing and plating costs, and fail to achieve the required 40 dB shielding level, especially in high-frequency ranges, and existing materials like lead alloys have low conductivity and complex manufacturing processes.
Innovation Solution
A copper ferrous (Fe—Cu) alloy rolled foil is developed, prepared by melting a Fe—Cu parent alloy with copper, adding a surface coating of anhydrous borax or cryolite to prevent oxidation, and undergoing multiple pass roll-milling to achieve a thickness of 100 μm to 10 μm, providing a high electromagnetic wave shielding effect of 80 dB or higher in the 1 GHz to 1.5 GHz range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper tape or aluminum tape is used for electromagnetic wave shielding, then the shielding effect is provided, but heat is generated and manufacturing costs increase
Solution Approach 1:
The patent uses a composite structure consisting of an iron tape layer and a copper plating layer. The iron tape provides the primary electromagnetic wave shielding effect, while the copper plating layer prevents corrosion and reduces heat generation through its superior thermal and electrical conductivity. This composite material approach resolves the contradiction by combining the high shielding capability of iron with the heat dissipation and corrosion resistance properties of copper.
2Reliability
If copper tape is used for electromagnetic wave shielding, then the shielding effect is provided, but the shielding level is insufficient (30 dB or lower) for controlling cables requiring 40 dB
Solution Approach 1:
The patent uses a composite structure combining iron tape and copper plating where the iron tape layer provides enhanced electromagnetic wave shielding capability compared to pure copper tape. The specific configuration of this composite material achieves the required 40 dB shielding level for controlling cables, resolving the contradiction between providing shielding effect and meeting the minimum shielding level requirement.
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 Fe—Cu alloy rolled foil offers superior electromagnetic wave shielding, improved corrosion resistance, and reduced manufacturing costs, enabling effective noise control in high-frequency ranges, thus enhancing the performance and reliability of cables used in electrical and communication systems.
Implementation Method 1
adding a surface coating of anhydrous borax or cryolite to prevent oxidation
Implementation Method 2
the Fe—Cu alloy is prepared by melting a Fe—Cu parent alloy with copper... providing a high electromagnetic wave shielding effect of 80 dB or higher
Data Source
AI summary
A rolled foil formed of the Fe—Cu alloy according to an embodiment of the present invention is manufactured to consist of 3 to 30 wt % iron and 70 to 97 wt % copper having a thickness of 100 μm to 10 μm, by casting a molten metal of a Fe—Cu parent alloy and a metal copper into a slab, heat-treating the slab, and roll-milling the heat-treated slab by using a multi-pass rolling mill with the total reduction ratio of 90% or higher. In this regard, the Fe—Cu alloy rolled foil according to the present invention provides an effect of shielding electromagnetic waves of 80 dB or more within high frequencies ranging between 1 GHz to 1.5 GHz.