Flexible Conductive Bonding Films for EMI Shielding
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Solution Overview
Problem
Existing flexible films and Faraday Cage structures face challenges in providing effective electromagnetic interference (EMI) shielding while preventing short-circuit issues, as they often have bond-line gaps and insufficient electrical conductivity.
Innovation Solution
A flexible film with an electrically conductive layer sandwiched between two electrically insulating layers, where the layers are partially intermixed in specific zones to create conductive surfaces for bonding and non-conductive surfaces elsewhere, ensuring efficient EMI shielding and preventing short-circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metallic Faraday Cage structure is used for EMI shielding, then electromagnetic interference shielding effectiveness is improved, but the risk of short-circuit increases due to bond-line gaps and insufficient electrical conductivity
Solution Approach 1:
The flexible film incorporates zones with different electrical properties: conductive zones where the conductive layer is exposed for EMI shielding and bonding to the fence, and insulating zones where the insulating layer is exposed to prevent short-circuits. This spatial differentiation of electrical properties allows the single film structure to simultaneously achieve both EMI shielding effectiveness and short-circuit prevention.
2Reliability
If the electrically conductive layer is fully exposed for bonding, then electrical conductivity and bonding strength are improved, but the risk of short-circuit increases
Solution Approach 1:
The film is designed with spatially differentiated zones: conductive zones where the conductive layer is exposed to provide electrical conductivity and bonding capability, and insulating zones where the insulating layer is exposed to prevent short-circuits. This local differentiation allows the film to simultaneously achieve strong electrical bonding where needed while preventing short-circuits where not needed.
3Reliability
If multiple separate components are used to achieve both conductivity and insulation, then functional performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the conductive layer and insulating layer into a single integrated flexible film structure. The conductive layer and insulating layer are positioned relative to each other in the same film, eliminating the need for separate components. This integration maintains both electrical conductivity and insulation functions while reducing overall structural complexity.
Solution Approach 2:
The flexible film serves multiple functions simultaneously: it provides EMI shielding through its conductive layer, enables bonding to the electrically conductive fence through conductive zones, and prevents short-circuits through insulating zones. This multi-functionality is achieved within a single film structure, eliminating the need for multiple separate components.
4Adaptability or versatility
If the layered structure is made flexible for adaptability, then ease of installation is improved, but manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The conductive layer and insulating layer are pre-positioned relative to each other during film manufacturing, establishing the correct spatial relationship before the film is applied to the device. This preliminary positioning ensures that when the flexible film is later installed and conformably attached to the fence, the conductive and insulating zones are already correctly aligned, maintaining manufacturing precision despite the film's flexibility.
Data Source
AI summary
Flexible films including an electrically conductive layer being sandwiched by two electrically insulating layers in a layered structure are provided. The layered structure extends continuously from at least one first zone to at least one second zone along a lateral direction of the flexible film, and the at least one first zone is positioned around a periphery of the respective at least one second zone. In the at least one first zone the three layers are at least partially intermixed with each other to provide an electrically conductive surface in the at least one first zone on the side of the first major surface of the layered structure, and in the at least one second zone the first major surface remains electrically non-conductive.