Flexible Ceramic Laminate Sheet for Electromagnetic Shielding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional ceramic sintered bodies used for electromagnetic shielding and NFC applications are brittle and lack flexibility, making them unsuitable for curved or flexible devices, and the processes to enhance flexibility, such as groove formation, are costly and inefficient, leading to material property deterioration and increased production costs.
Innovation Solution
A ceramic laminate sheet with a ferrite sheet divided by cracks formed without grooves, where a polymer resin layer is applied on both sides, and the sheet is pressurized to create a specific density of ceramic pieces, allowing for excellent flexibility in any direction without material property deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic sintered body is used for electromagnetic shielding and NFC applications, then electromagnetic wave absorption and eddy current suppression are achieved, but the material is too brittle and lacks flexibility, making it unsuitable for curved or flexible devices
Solution Approach 1:
The ceramic sheet is divided into multiple small pieces by forming cracks through pressurization, creating a segmented structure that allows flexibility while maintaining electromagnetic shielding performance. The ceramic pieces are held together by adhesive layers, enabling the sheet to bend and conform to curved surfaces without breaking.
Solution Approach 2:
The invention creates a composite structure combining ceramic pieces with polymer adhesive layers. This composite material integrates the electromagnetic shielding properties of ceramic with the flexibility of polymer, resolving the contradiction between rigidity and flexibility.
2Adaptability or versatility
If grooves are formed in ceramic green sheets using blade cutters or laser facilities to provide flexibility, then the ceramic sheet can be bent, but high-priced equipment is required and production cost increases
Solution Approach 1:
The invention replaces expensive mechanical groove-forming equipment (blade cutters, laser facilities) with a simple pressurization process. By applying pressure to the sintered ceramic sheet, cracks are formed automatically without requiring complex machining equipment, significantly reducing production costs.
Solution Approach 2:
The invention changes the approach from mechanical groove formation to pressure-induced crack formation. By controlling the pressurization parameters (pressure magnitude, application area), flexibility is achieved through crack patterns rather than grooves, simplifying the manufacturing process.
3Adaptability or versatility
If grooves are formed in ceramic green sheets to induce regular cracks and provide flexibility, then the ceramic sheet gains flexibility, but the tact time for groove forming is long and productivity decreases
Solution Approach 1:
The flexibility-enhancing cracks are formed after sintering rather than before, eliminating the need for time-consuming groove formation in green sheets. The pressurization process creates the necessary crack patterns in a single step after the ceramic is fully sintered, reducing total production time.
Solution Approach 2:
The invention extracts and eliminates the groove formation step from the manufacturing process. By forming cracks directly through pressurization of sintered sheets, the time-consuming groove machining operation is removed entirely, improving productivity.
4Adaptability or versatility
If the depth of grooves is controlled in thin ferrite sheets, then flexibility is achieved, but it becomes difficult to control groove depth and defects increase
Solution Approach 1:
The invention replaces the mechanical groove formation process (which requires precise depth control) with a pressurization process that creates cracks through controlled stress. This eliminates the need for precise depth control during manufacturing, as the crack formation is governed by material strength properties rather than mechanical tool depth settings.
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 significantly reduces production costs and time, maintains ceramic material properties, and enables easy attachment to both flat and curved devices with superior flexibility and performance in applications like NFC and electromagnetic shielding.
Implementation Method 1
forming a plurality of cracks in the ceramic sheet by pressurizing the laminate sheet to divide the ceramic sheet into a plurality of pieces
Data Source
Figure 1~3(b)
Figure 4~6
Figure 7~8
AI summary
Disclosed is a ceramic laminate sheet (100) comprising a ceramic sheet (110) having a plurality of cracks (111) and a polymer resin layer (120) disposed on one side or both sides of the ceramic sheet (110), wherein the plurality of cracks (111) pass through the ceramic sheet from one side to the other side thereof, the cracks (111) divide the ceramic sheet (110) into a plurality of pieces, grooves for formation of the cracks are not provided in one side and the other side of the ceramic sheet (110).