Fiber-Reinforced Polymer for EMI Shielding and Thermal Management
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Solution Overview
Problem
Electronic modules in automotive vehicles face challenges with added cost and weight due to the need for separate EMI shields and heat sinks, which are not efficiently combined for electromagnetic interference shielding and thermal conductivity.
Innovation Solution
A fiber-reinforced polymer composition with thermally conductive fillers and long, electrically conductive fibers distributed within a polymer matrix, providing both electromagnetic shielding and thermal conductivity, thereby potentially replacing the need for additional components like EMI shields and heat sinks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate EMI shields and heat sinks are added to protect electronic components, then electromagnetic shielding effectiveness and thermal conductivity are improved, but device complexity and weight increase
Solution Approach 1:
The patent combines EMI shielding and thermal management functions into a single housing component by incorporating electrically conductive fibers (for EMI shielding) and thermally conductive filler (for heat dissipation) into the polymer matrix, eliminating the need for separate EMI shields and heat sinks
Solution Approach 2:
The housing is designed to perform multiple functions simultaneously: structural support, EMI shielding through conductive fibers, and thermal management through thermally conductive filler, making it a multi-functional component that replaces several separate parts
2Reliability
If separate EMI shields and heat sinks are added to electronic modules, then electromagnetic shielding and thermal conductivity are improved, but weight increases
Solution Approach 1:
The patent merges thermal management and EMI shielding functions into the housing structure itself, using thermally conductive filler and conductive fibers embedded in the polymer matrix, thereby eliminating the weight of separate heat sinks and EMI shields
Solution Approach 2:
The housing is made from a composite material consisting of polymer matrix, thermally conductive filler (such as aluminum oxide or boron nitride), and electrically conductive fibers (such as steel or copper fibers), which provides both thermal conductivity and EMI shielding properties in a single lightweight structure
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 composition achieves high thermal conductivity and electromagnetic shielding effectiveness while maintaining low weight and cost, with enhanced mechanical properties, making it suitable for use in electronic modules such as radar and lidar modules.
Implementation Method 1
a thermally conductive filler distributed within the polymer matrix; the composition exhibits an in-plane thermal conductivity of about 1 W/m-K or more
Implementation Method 2
a plurality of long fibers distributed within the polymer matrix. The long fibers comprise an electrically conductive material; the composition exhibits an electromagnetic shielding effectiveness of about 20 dB or more
Data Source
AI summary
A fiber-reinforced polymer composition that comprises a polymer matrix; a thermally conductive filler distributed within the polymer matrix; and a plurality of long fibers distributed within the polymer matrix is provided. The long fibers comprise an electrically conductive material and have a length of about 7 millimeters or more. Further, the composition exhibits an in-plane thermal conductivity of about 1 W/m-K or more as determined in accordance with ASTM E 1461-13 and an electromagnetic shielding effectiveness of about 20 dB or more as determined at a frequency of 1 GHz in accordance with EM 2107A.