Insulating Composite Plate with Metal Mesh Shielding
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Solution Overview
Problem
Existing insulating plates lack the ability to provide both effective insulation and electromagnetic shielding, often requiring separate materials for each function, which can increase weight and energy consumption due to the use of metal plates for shielding.
Innovation Solution
A composite plate structure comprising a thermoplastic material for the upper and lower layers and a metal mesh in between, bonded together in a molten state to create a lightweight insulating composite plate with electromagnetic shielding capabilities, suitable for applications like battery pack covers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If metal plates are used for electromagnetic shielding, then electromagnetic shielding capability is improved, but weight increases
Solution Approach 1:
The patent uses a composite structure consisting of a metal mesh layer embedded between two thermoplastic resin layers. This composite material approach provides electromagnetic shielding through the metal mesh while the thermoplastic layers reduce overall weight compared to solid metal plates, directly resolving the contradiction between shielding capability and weight.
Solution Approach 2:
Instead of using a solid metal plate throughout, the patent employs a metal mesh with specific opening patterns (20-400 openings per unit area). This local quality approach provides electromagnetic shielding where needed through the metal strands while allowing the thermoplastic material to fill the spaces, reducing weight while maintaining shielding effectiveness.
2Object-affected harmful factors
If separate materials are used for insulation and electromagnetic shielding, then functional performance is improved, but device complexity increases
Solution Approach 1:
The patent merges the insulation function and electromagnetic shielding function into a single integrated composite plate structure. The thermoplastic resin layers provide insulation while the embedded metal mesh provides electromagnetic shielding, eliminating the need for separate insulating plates and shielding plates, thus reducing structural complexity while maintaining both functions.
Solution Approach 2:
The composite plate structure serves multiple functions simultaneously: the thermoplastic resin layers provide electrical insulation and structural support, while the embedded metal mesh provides electromagnetic shielding. This multi-functionality allows a single component to replace what would traditionally require multiple separate components.
3Object-affected harmful factors
If metal mesh is embedded in thermoplastic material, then electromagnetic shielding is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes the phase transition of thermoplastic resin from solid to molten state during molding, then back to solid upon cooling. The metal mesh is embedded while the resin is in its molten state, allowing easy integration. After molding and cooling, the resin solidifies and locks the metal mesh in place. This phase transition approach simplifies the embedding process compared to mechanical assembly methods.
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 composite plate achieves excellent insulation and electromagnetic shielding while reducing weight and energy consumption, maintaining a strong bond between layers to prevent moisture ingress and corrosion, suitable for electric vehicle battery packs.
Implementation Method 1
the thermoplastic material on the upper plate layer and/or the lower plate layer penetrates the openings of the metal mesh in a molten state, and comes into contact with the lower plate layer or the upper plate layer on the other side of the metal mesh; after the thermoplastic material in a molten state is solidified, the upper plate layer is integrated with the lower plate layer
Data Source
AI summary
The present application provides an insulating composite plate comprising: an upper plate layer, a lower plate layer, and a middle plate layer, wherein the upper plate layer and the lower plate layer are made of a thermoplastic material; the middle plate layer is located between the upper plate layer and the lower plate layer, the middle plate layer being a metal mesh; the upper surface of the middle plate layer and the lower surface of the upper plate layer are bonded together, and the lower surface of the middle plate layer and the upper surface of the lower plate layer are bonded together. An insulating composite plate provided by this application has good insulation properties and can shield electromagnetic interference.