Fiber-Reinforced Shielding Structure for Complex Molded Shapes
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Solution Overview
Problem
Existing technologies face challenges in creating a vehicle structure with effective electromagnetic wave and magnetic field shielding due to issues such as insufficient conductivity, inability to follow complex shapes, increased assembly time, heavy magnetic materials, and gaps in metal layers, which affect the shielding performance and manufacturing efficiency.
Innovation Solution
An integrally molded article comprising a fiber-reinforced resin layer with a shielding layer containing an aggregate of metal strips dispersed in a matrix resin, allowing for complex shapes and improved conductivity, with specific dimensions and proportions for the metal strips to enhance shielding effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin metal foil pieces are simply mixed in the resin molded article, then the manufacturing process is simplified, but the conductivity and shielding property are reduced
Solution Approach 1:
The metal shielding layer is segmented into fine metal strips (0.01-0.1mm thick) that are dispersed throughout the resin molded article. This segmentation allows the metal pieces to be easily mixed into the resin during molding while still maintaining sufficient conductivity when properly distributed, resolving the contradiction between manufacturing simplicity and shielding effectiveness
Solution Approach 2:
The patent applies different metal strip configurations in different regions of the molded article. The metal strips are concentrated in areas requiring higher shielding (such as near battery components) while maintaining overall distribution throughout the structure. This local quality approach ensures adequate shielding property without requiring uniform high metal content throughout the entire article, balancing manufacturing ease with performance requirements
2Shape
If the shielding layer is pre-shaped and adhered to the molded article, then the shielding layer can follow complex shapes, but the assembly time increases
Solution Approach 1:
The patent merges the shielding layer formation with the resin molding process itself. The fine metal strips are mixed into the resin material before molding, and the entire shielding layer is formed simultaneously with the molded article in a single injection molding operation. This eliminates the separate steps of pre-shaping and adhering the shielding layer, reducing assembly time to zero while maintaining the ability to follow complex shapes through the molding process
Solution Approach 2:
The metal strips are preliminarily mixed into the resin material in the appropriate distribution pattern before the molding process begins. This preliminary action ensures that when the resin is injected and molded, the metal strips are already positioned to follow the complex geometry of the final part, eliminating the need for subsequent shaping or adherence operations
3Reliability
If metal strips with larger dimensions are used, then the conductivity is improved, but the shielding layer becomes heavier and less adaptable to complex shapes
Solution Approach 1:
The patent changes the dimensional parameters of the metal elements from large sheets or thick foils to fine strips with thickness of 0.01-0.1mm, length of 1-100mm, and width of 0.1-10mm. This parameter change reduces the weight and flexibility issues of larger metal pieces while maintaining conductivity through optimized distribution. The fine strip configuration provides sufficient conductive pathways without the weight penalty of larger metal components
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 enables the production of a vehicle structure with enhanced electromagnetic wave and magnetic field shielding, maintaining high conductivity and stability even in complex shapes, reducing assembly time, and improving manufacturing efficiency.
Implementation Method 1
the property of shielding against an electric field or a magnetic field increases as the conductivity of the material increases
Implementation Method 2
An integrally molded article including a fiber-reinforced resin layer containing reinforcing fibers and a first matrix resin
Data Source
Figure 1~2A
Figure 2B~3
Figure 4
AI summary
Provided is an integrally molded body that has a blocking layer for cutting off radio waves and magnetic waves. This integrally molded body comprises a fiber-reinforced resin layer containing reinforcing fibers and a first matrix resin, and a blocking layer, wherein the blocking layer contains an aggregate of metal strips and a second matrix resin, and blocks at least one of an electric field or a magnetic field, the metal strips being dispersed in the surface of the blocking layer to form the aggregate.