Conductive Polymer Fiber Mesh Cable Shielding
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Solution Overview
Problem
Conventional cables with metal and aluminum foil shielding layers are ineffective in shielding electromagnetic waves generated by energized wires, leading to interference with surrounding electronic equipment.
Innovation Solution
A cable with an electromagnetic shielding layer made of conductive polymer fibers, formed by extruding and curing a mixture of polypropylene, polyester, acrylic acid, polyamide, and viscose fibers, which provides enhanced electromagnetic interference protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a combination of metal and aluminum foil is used for the shielding layer, then the shielding structure is established, but the electromagnetic shielding performance is insufficient
Solution Approach 1:
The patent changes the material parameter from traditional metal and aluminum foil to conductive polymer, fundamentally altering the electromagnetic interaction characteristics. The conductive polymer's unique electrical conductivity and dielectric properties enable superior electromagnetic wave absorption and shielding performance compared to conventional metallic materials.
Solution Approach 2:
The patent employs composite material structure by combining conductive polymer with fiber mesh architecture. This composite approach integrates the electromagnetic shielding capabilities of conductive polymer with the structural integrity and flexibility of fiber mesh, achieving both high shielding performance and mechanical durability.
2Reliability
If traditional metal and aluminum foil shielding materials are used, then shielding coverage is achieved, but the shielding effectiveness against electromagnetic waves is poor
Solution Approach 1:
The patent transforms the shielding mechanism by changing from reflective shielding (metal/foil) to absorptive shielding (conductive polymer). This parameter change in the shielding mechanism allows the material to absorb electromagnetic energy and convert it to heat, preventing re-radiation and providing superior shielding effectiveness.
Solution Approach 2:
The patent replaces the traditional metallic shielding system with a polymer-based system that operates on different physical principles. The conductive polymer utilizes electrical conductivity and dielectric loss mechanisms rather than simple electromagnetic reflection, substituting the mechanical/physical shielding approach with a more sophisticated electromagnetic interaction mechanism.
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 conductive polymer fiber mesh effectively reduces electromagnetic wave intensity below the threshold, offering improved shielding performance while being lightweight, flexible, and environmentally friendly.
Implementation Method 1
When a conventional cable is energized, the cable would interfere with surrounding electronic equipments with the electromagnetic waves generated by the electromagnetic induction effect. Therefore, most of the materials of a shielding layer used to cover the wires in the cable are a combination of metal and aluminum foil to shield electromagnetic waves.
Implementation Method 2
melting the conductive polymer; extruding the molten conductive polymer to form a plurality of conductive polymer fibers
Implementation Method 3
extruding the molten conductive polymer to form a plurality of conductive polymer fibers
Implementation Method 4
curing the plurality of the conductive polymer fibers to form the electromagnetic shielding layer covering the wire
Data Source
AI summary
A cable includes a wire and an electromagnetic shielding layer. The electromagnetic shielding layer covers the wire. The electromagnetic shielding layer is in the form of fiber mesh, including a conductive polymer. A manufacturing method includes: feeding the conductive polymer, melting the conductive polymer, extruding the molten conductive polymer to form a plurality of conductive polymer fibers, covering the wire with the plurality of conductive polymer fibers, and curing the plurality of the conductive polymer fibers to form the electromagnetic shielding layer covering the wire. The electromagnetic shielding layer of the cable of the present application replaces current aluminum foil shielding and metal shielding for conventional wires, decreasing interference by electromagnetic waves produced by electromagnetic induction on electronic devices nearby.