Noise Suppression Sheet With Misaligned Composite Layers
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Solution Overview
Problem
As digital circuit operation speeds increase, electronic apparatuses face erroneous operations and adverse human effects due to electromagnetic noise, necessitating an effective noise suppression solution.
Innovation Solution
A noise suppression sheet with a novel configuration comprising composite layers of insulating resin, non-magnetic metal, and metal magnetic layers, featuring through holes that are misaligned between layers and having a multilayer structure on the inner surfaces, which effectively absorbs and reflects electromagnetic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-layer noise suppression structure is used, then the structure is simple, but the noise suppression effectiveness is insufficient and the structure cannot be sufficiently thinned
Solution Approach 1:
The noise suppression sheet is divided into multiple composite layers, each containing an insulating resin layer, a non-magnetic metal layer, and a metal magnetic layer. This segmentation allows each layer to contribute differently to noise suppression (reflection from non-magnetic layer, absorption from magnetic layer) while enabling the overall structure to be thinner and more effective than a single-layer design.
Solution Approach 2:
The patent employs composite layers combining insulating resin, non-magnetic metal, and metal magnetic materials. This composite structure leverages the complementary properties of each material: the insulating resin provides dielectric properties and structural integrity, the non-magnetic metal layer reflects electromagnetic noise, and the magnetic metal layer absorbs noise, achieving superior noise suppression effectiveness.
2Reliability
If air layers are present between composite layers, then manufacturing is easier, but frequency dependence of the dielectric constant increases and noise suppression performance deteriorates
Solution Approach 1:
The insulating resin layer contains voids (porous structure) that are filled with conductive liquid during manufacturing. This porous structure allows the conductive liquid to penetrate and bond the composite layers together, eliminating air layers while maintaining manufacturing feasibility. The conductive liquid fills the voids and creates reliable electrical and mechanical connections between layers.
Solution Approach 2:
The conductive liquid acts as an intermediary substance that fills the voids in the insulating resin layer and bonds the composite layers together. This intermediary material eliminates air layers between layers, prevents frequency dependence issues, while simplifying the manufacturing process by providing a liquid-state bonding agent that can be easily applied.
3Length of moving object
If the sheet is thinned to reduce size, then the apparatus size is reduced, but the noise suppression effectiveness may be compromised
Solution Approach 1:
By dividing the noise suppression sheet into multiple thin composite layers, each layer can be made sufficiently thin while collectively maintaining adequate total thickness for effective noise suppression. The segmented structure allows optimization of each layer's thickness for its specific function (reflection, absorption) while achieving overall thinness.
Solution Approach 2:
The composite layer structure combines materials with complementary noise suppression mechanisms (reflection from non-magnetic metal, absorption from magnetic metal) in a thin configuration. This composite approach maximizes noise suppression effectiveness per unit thickness, enabling the sheet to be thinned while maintaining or improving performance.
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 sheet achieves excellent magnetic shielding characteristics, allowing for thinning while maintaining effective noise suppression across a high frequency band, reducing frequency dependence of the dielectric constant and preventing air layer formation between layers.
Implementation Method 1
a non-magnetic metal layer 20, and a metal magnetic layer 30 formed on the non-magnetic metal layer 20... effectively absorbs and reflects electromagnetic noise
Implementation Method 2
a metal magnetic layer 30 formed on the non-magnetic metal layer 20... effectively absorbs and reflects electromagnetic noise
Data Source
AI summary
A noise suppression sheet comprises at least one composite layer, the composite layer including: an insulating resin layer; a non-magnetic metal layer formed on the insulating resin layer; and a metal magnetic layer formed on the non-magnetic metal layer, and the composite layer has a through hole. When the noise suppression sheet comprises a plurality of composite layers, the through holes are misaligned in adjacent composite layers in the laminating direction.