Electromagnetic Shielding Laminate via Single-Step Overmoulding
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Solution Overview
Problem
Existing methods for producing electromagnetic radiation shielding composites often require multiple process steps and may not provide adequate mechanical properties or flexibility in adapting to different electromagnetic field requirements.
Innovation Solution
A method for producing a layered composite that integrates a conductive insert between two plastic layers, allowing for single-step formation and overmoulding with thermoplastic material, using organo sheets or plastic films with embedded fibers and a conductive insert, such as metal grids or fibers, to create a component with enhanced mechanical properties and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple process steps are used to produce shielding composites (adding conductive additives to polymer, then applying conductive coatings, or deep-drawing followed by inserting wire mesh), then shielding properties can be achieved, but the production complexity and number of process steps increase
Solution Approach 1:
The patent combines multiple previously separate process steps into a single injection molding process. The conductive insert, plastic layers, and sealing elements are all formed and assembled in one manufacturing step, eliminating the need for separate additive mixing, coating application, and assembly operations that were required in conventional methods
Solution Approach 2:
The conductive insert is pre-formed with the necessary geometry and conductivity properties before being integrated into the injection molding process. This preliminary preparation allows the insert to be precisely positioned and integrated into the final component during the single molding operation, simplifying the overall production process
2Ease of manufacture
If conventional plastic materials are used without conductive additives, then the material remains electrically insulating and easy to process, but electromagnetic radiation shielding is not provided
Solution Approach 1:
The patent employs a composite structure consisting of non-conductive plastic layers combined with a conductive insert. This composite approach allows the plastic to maintain its excellent processability and insulating properties while the embedded conductive insert provides the necessary electromagnetic shielding, achieving both requirements simultaneously
Solution Approach 2:
The conductive properties are localized to specific regions where the conductive insert is placed within the plastic component. This allows the majority of the component to remain made of easy-to-process plastic material, while only the specific areas requiring shielding have conductive characteristics, maintaining overall ease of manufacture
3Ease of manufacture
If standard injection molding is used without integrated forming of multiple layers, then production is simple, but the mechanical properties and adaptability to electromagnetic field requirements are insufficient
Solution Approach 1:
The patent segments the component into distinct functional layers (plastic layers and conductive insert) that are formed separately and then integrated through injection molding. This segmentation allows each layer to be optimized for its specific function while the multi-layer construction enhances overall mechanical properties compared to homogeneous materials
Solution Approach 2:
The injection molding process is designed to perform multiple functions simultaneously: forming the plastic layers, positioning the conductive insert, creating sealing elements, and integrating all components into a single assembled part. This multi-functionality maintains production simplicity while achieving superior mechanical properties and electromagnetic shielding adaptability
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
Enables the production of shielding components with improved mechanical properties and flexibility, allowing for one-shot injection molding and adaptation to specific electromagnetic field requirements, resulting in effective electromagnetic radiation shielding.
Implementation Method 1
heating (S2) of the layered composite to a forming temperature by means of a heating device
Implementation Method 2
forming (S3) of the layered composite into a predetermined shape by means of a forming device
Implementation Method 3
an insert (16) arranged between the first plastic layer (12) and the second plastic layer (14), the insert (16) being designed to shield electromagnetic radiation
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing a laminate (10) for shielding electromagnetic radiation. The method comprises arranging (S1) a first layer of plastic (12), a second layer of plastic (14) and an insert (16) arranged between the first and second layers of plastic, wherein the insert (16) is designed for shielding electromagnetic radiation. The method further comprises heating up (S2) the laminate (10) to a moulding temperature by means of a heating device and moulding (S3) the laminate (10) into a predetermined shape by means of a moulding device. The invention also relates to a corresponding laminate (10) for shielding electromagnetic radiation.