Permalloy Shielding Assembly for Low-Frequency Battery EMI
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Solution Overview
Problem
Conventional electromagnetic shielding films struggle to achieve effective shielding for extremely low-frequency electromagnetic waves, such as those below 100 kilohertz, and often become hard and difficult to process due to alloy plating limitations.
Innovation Solution
The development of electromagnetic energy mitigation assemblies featuring a multilayer structure with first and second permalloy layers on opposite sides of electrically conductive layers, along with an electromagnetic noise suppression layer sandwiched between the permalloy layers, enhancing shielding effectiveness and maintaining softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional electromagnetic shielding films are used, then shielding for high frequency waves is achieved, but shielding effectiveness for extremely low frequency waves (less than 100 kHz) is poor
Solution Approach 1:
The patent employs a composite structure consisting of multiple permalloy layers (high magnetic permeability material) alternating with electrically conductive layers. This composite material design enables the shielding film to effectively attenuate extremely low frequency electromagnetic waves through magnetic shielding mechanisms while maintaining structural integrity and flexibility.
Solution Approach 2:
The patent applies different material properties to different layers of the shielding film: permalloy layers provide high magnetic permeability for low frequency shielding, while electrically conductive layers provide electrical conductivity for high frequency shielding. This local differentiation of material qualities enables broad-spectrum shielding effectiveness.
2Object-affected harmful factors
If alloy plating is applied to improve shielding effectiveness, then shielding performance increases, but the film becomes hard and difficult to process
Solution Approach 1:
The patent changes the material composition parameters by using permalloy (a nickel-iron alloy with specific proportions) instead of conventional heavy alloy platings. This parameter change maintains high shielding effectiveness while improving the mechanical properties and processability of the shielding film.
Solution Approach 2:
By creating a composite structure with alternating permalloy and electrically conductive layers, the patent achieves effective shielding without requiring thick, hard alloy platings. The composite design maintains film flexibility and ease of manufacturing while providing superior shielding 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 multilayer structure achieves shielding effectiveness greater than 20 decibels at frequencies from 10 to 30 kilohertz, with a prototype showing 38 decibels at 30 kilohertz, while maintaining softness, as demonstrated by reduced force required for deflection.
Implementation Method 1
To shield interference from an external electromagnetic wave, it is common practice to attach an electromagnetic shielding film on electronic equipment
Implementation Method 2
First and second permalloy layers are along respective first and second opposite sides of the first electrically conductive layer. Third and fourth permalloy layers are along respective third and fourth opposite sides of the second electrically conductive layer
Data Source
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AI summary
This application discloses electromagnetic energy mitigation assemblies and automotive vehicle components comprising the electromagnetic energy mitigation assemblies. An electromagnetic energy mitigation assembly includes a first electrically conductive layer and a second electrically conductive layer. First and second permalloy layers are along respective first and second opposite sides of the first electrically conductive layer. Third and fourth permalloy layers are along respective third and fourth opposite sides of the second electrically conductive layer. An electromagnetic noise suppression layer is sandwiched between the second and third permalloy layers. An automotive vehicle component includes an electromagnetic energy mitigation assembly configured to be positioned relative to one or more batteries of an automotive vehicle for providing electromagnetic shielding for the one or more batteries. The electromagnetic energy mitigation assembly includes a first electrically conductive layer. First and second permalloy layers are along respective first and second opposite sides of the first electrically conductive layer.