Electromagnetic interference shielding sheet molding composition

In accordance with the present invention, there is provided an electromagnetic shielding composition. The electromagnetic shielding composition in accordance with the broad aspects of the present invention includes from about 40% to 60% by volume of a sheet molding composition filled with an effective amount of carbon fibers for shielding of electromagnetic radiation from the electrical systems in an at least partially electrically driven vehicle.

FIELD OF THE INVENTION

The present invention relates to shielding of electromagnetic interference in electric and hybrid vehicles. More particularly, the present invention relates to a sheet molding composition useful in electromagnetic shielding of components in a vehicle.

BACKGROUND OF THE INVENTION

Managing electric fields generated in vehicles has long been a consideration when building vehicles with internal combustion engines. Any time current is generated in an electrical system, there is also a subsequent electric field related to the current generation. These fields can interfere with other electrical components and systems in a vehicle.

Certain electrical components are more sensitive to the fields than others. For instance, in operating a vehicle radio on AM or FM bands, spark plug interference is prevalent at times. Resistance spark plugs knocks down the interference as well as using spark plug wires designed to reduce background electrical noise.

As vehicle systems and society in general become increasingly reliant on electrical controls and monitoring cages and systems, the need to further manage and limit electromagnetic interference has also become much more important and even critical to ensuring correct operation of electrical devices in or in close proximity to the vehicle.

With the advent of electric hybrid and pure electric powered vehicles, the current used in such vehicles is magnitudes more than used in conventional vehicles. The motors used and the batteries, wires, relays solenoids and other components must be extremely robust in order to effectively and reliably handle the electrical energy necessary to power and run the systems in the vehicle. Therefore, the electric fields produced by these systems have increased. While modern engineering and materials have helped control some of the electrical field emissions, there remains a need to further control and or shield or isolate gauges, radios, lighting, and occupants from the electrical fields generated.

In particular, most EV batteries, battery management systems, traction motor controllers and DC-DC converters are connected to devices or are devices that are switching high power (up to 100 kW or more) at high frequencies (20-50 kHz). This results in electromagnetic fields, at these frequencies and harmonics, that may radiate from the devices and these radiations could interfere with safety, communication, and entertainment equipment. This could occur both on board and off board the vehicle. The allowable level of emissions is controlled through regulation (e.g., FCC) and product performance specifications.

Standard practice in enclosure design is to use metals or coat plastic or composite enclosures with metal. Semi-structural battery housings used in these vehicles have used glass reinforced SMC with a shielding layer, typically copper. This is a robust yet expensive and heavy solution. Therefore, there remains a need in the art to replace heavy and expensive copper shielding designs with a more cost effective and lighter material without sacrificing shielding characteristics.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided an electromagnetic shielding composition. The electromagnetic shielding composition in accordance with the broad aspects of the present invention includes from about 40% to 60% by volume of a Sheet Molding composition filled with an effective amount of carbon fibers for shielding of electromagnetic radiation from the electrical systems in an at least partially electrically driven vehicle.

Also provided in the present invention is a process for making an electromagnetic shield for a component of an electrical vehicle. In the process of the present invention, an electromagnetic shielding composition in the form of a sheet is formulated. The electrical shielding composition includes from about 40% to 60% by volume of a sheet molding composition filled with an effective amount of carbon fibers for shielding of electromagnetic radiation from the electrical systems in an at least partially electrically driven vehicle. Thereafter, an electromagnetic shield for a part is produced by forming and curing the sheet of electromagnetic shielding composition into a shape effective for following the form of a component to be shielded.

Using carbon fiber as a reinforcement in place of glass and reduce the mass of the part through the lower density and higher strength of carbon fiber. The present invention also eliminates the copper cladding in prior designs by taking advantage of the potential of carbon fiber to attenuate EMI. This would further reduce mass of parts manufactured and partially off-set the cost of the carbon fiber.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, in accordance with the present invention, there is provided an electromagnetic shielding composition, generally shown at10for molding of a shield12of an electrical component of a vehicle not shown. The shield12shown inFIG. 1is a cover for a battery box of an electric vehicle. The sheet molding composition of the present invention provides molding of complicated shape applications. The material is compatible with epoxy resins and unidirectional fiber formats for local reinforcement. It also is E-coat temperature capable with long term stability.

The electromagnetic shielding composition, in accordance with the broad aspects of the present invention, includes from about 40% to 60% by volume of a Sheet Molding composition filled with an effective amount of carbon fibers for shielding of electromagnetic radiation from the electrical systems in an at least partially electrically driven vehicle. Generally, from about 60% to about 40% of a shielding carbon fiber material. Typically, in from about 45% to about 55% SMC blended with from about 55% to about 45% carbon fiber is used with a particularly preferred ratio of about 50% SMC and 50% carbon fiber.

As best shown inFIG. 2, compounded sheets, made in accordance with the present invention, are typically from about 0.5 mm to about 10 mm thick depending on the shielding desired preferred sheets are 1 mm to 2 mm thick. The shielding generated is from about a 65 to 85 decibel reduction from a 1-2 mm thickness over a frequency range of 1000 MHz to 2000 MHz.

A particularly preferred SMC compound is a Magna EPIC Blend™ SMC composition available from Magna International, Novi, Mich. The SMC is a Vinyl Ester type sheet molding composition. Other fillers, additives and components may be included in minor amounts provided they do not affect the physical and particularly the electric field shielding properties of the present invention.

The properties of the resulting composition are set forth below in Table 1:

Carbon fibers selected for the present invention are those suitable for formulation with the SMC chosen and which provide suitable shielding properties.

A particularly preferred material for use in the present invention is a Panex (circle R) 35 continuous Tow (50K) 35 carbon fiber material available from Zoltek Companies, Inc. St. Louis, Mo. This material is a 50 K filament fiber manufactured from polyacrylonitrile precursor. The material has a tensile strength of 600 KSI, a tensile modulus of 35 Msi, an electrical resistivity of 0.00061 ohm-in, a fiber diameter of 0.283 mils, a carbon content of 95%, and a yield of 400 ft/lb.

In accordance with the process aspects of the present invention, there is provided a process for making an electromagnetic shield for a component of an electrical vehicle. The first step is to provide an electromagnetic shielding composition in the form of a sheet. Blending of SMC and chopped carbon fibers are used in the present invention. As set forth above, electrical shielding composition including from about 40% to 60% by volume of a sheet molding composition is filled with an effective amount of carbon fibers for shielding of electromagnetic radiation from the electrical systems in an at least partially electrically driven vehicle and is formed into a sheet. The sheet is thereafter formed into a predetermined shape and then cured at a tool temperature of about 150 degrees C. The sheet of electromagnetic shielding composition is formed into a shape effective for following the form of a component to be shielded.

The component to be shielded is either an electrical component to be installed in a vehicle such as a radio, gauge, control unit or the like which would have a shielded housing. Or the shielding may be formed in a shape to cover a motor, feed wire, battery, a group of batteries, a wire, a wiring harness or other heavy current using systems. It may be particularly desirable to provide contoured shields for control units in the electric vehicle such as an engine control unit, a computer device, a transmission control unit, a charging control unit.

EXAMPLE

Shielded Sheet Molding compositions are made in containing 40% 45%, 50%, 55% and 60% Sheet molding composition with the remainder carbon fibers 1 inch to about 3 inches long and ranging from 0.5 mm to 10 mm thick and 1 mm to 2 mm thicknesses. Decibel reductions are found to be 65-85 over a frequency range of 1000 Mhz to 2000 Mhz. Sheets and parts are formed of the material and cured at a temperature of about 150 degrees C. The parts are found effective in electromagnetic shielding of parts in an electric and hybrid vehicle.