Incised EMI Shielding Laminate for 3D Stretch Without Tearing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing laminates for electromagnetic shielding lack high stretchability and are prone to tearing when applied to complex three-dimensional objects, leading to compromised shielding effectiveness.
Innovation Solution
A flexible laminate comprising a metal foil and a sheet-like substrate with strategically arranged incisions, allowing for improved flexibility and electromagnetic shielding by enabling stretching in multiple directions without material removal, and allowing for the laminate to be shaped and bonded to components in a single process step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laminates are made from metal foil and substrate without incisions, then electromagnetic shielding effectiveness is maintained, but stretchability is limited and tear propagation occurs during deformation
Solution Approach 1:
The laminate is divided into multiple segments by creating incisions that extend partially through the thickness. These incisions create discrete segments connected by bridges, allowing each segment to move independently during stretching while maintaining overall structural integrity and shielding effectiveness.
Solution Approach 2:
The patent employs thin film structures with controlled incisions that enable flexible deformation. The incised thin film laminate can be stretched and conform to complex three-dimensional surfaces while the metal foil layers maintain electromagnetic shielding through their continuous conductive paths.
2Adaptability or versatility
If incisions are made into the laminate to improve flexibility, then stretchability increases, but shielding effectiveness may be compromised
Solution Approach 1:
The incisions are designed with varying characteristics at different locations and depths. Some incisions extend fully through certain layers while others are partial, creating local variations in flexibility and conductivity that optimize both adaptability to complex shapes and maintenance of shielding effectiveness.
Solution Approach 2:
The laminate combines multiple materials with different properties: metal foil layers for electromagnetic shielding, substrate materials for structural support, and adhesive layers for bonding. The composite structure allows each material to contribute its optimal properties while working together to achieve both flexibility and shielding effectiveness.
3Reliability
If traditional metallic shielding is used, then electromagnetic compatibility is achieved, but material weight and manufacturing complexity increase
Solution Approach 1:
The patent uses thin metal foil layers integrated into a flexible laminate structure, replacing traditional thick metallic shields. This thin-film approach maintains electromagnetic compatibility through the conductive metal layers while dramatically reducing material weight and enabling flexible deformation.
Solution Approach 2:
The laminate combines lightweight substrate materials with thin metal foil layers, creating a composite structure that achieves electromagnetic shielding effectiveness with minimal weight. The composite design allows optimization of each layer's thickness and material properties to balance shielding performance and weight reduction.
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 laminate achieves high stretchability and effective electromagnetic shielding, preventing tear propagation and maintaining shielding integrity even when deformed, making it suitable for complex shapes and applications in electric vehicles and electronics.
Implementation Method 1
a) at least one metal foil; the laminate has a plurality of objects formed by incisions into a base area of the laminate... for shielding electromagnetic radiation
Data Source
AI summary
A flexible laminate for shielding against electromagnetic radiation includes: a) at least one metal foil; and b) a sheet-like substrate made of a fiber material, film material, or foam material. The laminate includes a plurality of objects formed by incisions into a base area of the laminate. Each object of the plurality of objects is made of two or more incisions having a common initial point. The two or more incisions, or each of two adjacent incisions of the two or more decisions, define an angle of 45° to 160°.