Electromagnetic energy mitigation assemblies and automotive vehicle components including the same

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.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Chinese Utility Model Application No. 202222506579.1 filed Sep. 21, 2022 (granted on Feb. 28, 2023 as Chinese Utility Model Patent No. ZL 202222506579.1), which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present application generally relates to the technical field of electromagnetic shielding, and in particular to electromagnetic energy mitigation assemblies and automotive vehicle components including the same.

BACKGROUND

To shield interference from an external electromagnetic wave, it is common practice to attach an electromagnetic shielding film on electronic equipment. But as recognized herein, it tends to be difficult for conventional electromagnetic shielding films to achieve good shielding effectiveness for electromagnetic waves of extremely low frequency (e.g., less than 100 kilohertz (kHZ), etc.).

SUMMARY

Exemplary embodiments are disclosed of electromagnetic energy mitigation assemblies. In an exemplary embodiment, 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.

Also disclosed are exemplary embodiments of automotive vehicle components including electromagnetic energy mitigation assemblies. In an exemplary embodiment, 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.

DETAILED DESCRIPTION

As noted above, it is common practice to attach an electromagnetic shielding film on electronic equipment to shield interference from an external electromagnetic wave. But as recognized herein, it tends to be difficult for conventional electromagnetic shielding films to achieve good shielding effectiveness for electromagnetic waves of extremely low frequency (e.g., less than 100 kilohertz (kHZ), etc.).

For example, a conventional electromagnetic noise absorbing elastomer film having a thickness of 0.2 mm may have only a shielding effectiveness of only 3 dB against an electromagnetic wave with a frequency of 30 kHz. A conventional electromagnetic shielding film plated with alloy may provide a better shielding effect at extremely low frequency electromagnetic waves. But the alloy plating processes may limit the maximum plating thickness. And alloy plating layers with high thicknesses then to be relatively hard, which therefore reduces the softness of the electromagnetic shielding films making it difficult and inconvenient to process, use, and adhere to the electromagnetic shielding films to electronic equipment.

After recognizing the above, exemplary embodiments were developed and are disclosed herein of electromagnetic energy mitigation assemblies (e.g., multilayer electromagnet shielding films, multilayered electromagnetic shielding structures, etc.) that may help to solve the above-noted technical problems associated with poor shielding effectiveness of electromagnetic shielding films for extremely low frequency electromagnetic waves.

In exemplary embodiments, an electromagnetic energy mitigation assembly first and second electrically conductive layers (e.g., first and second copper layers, etc.). First and second permalloy layers (e.g., first and second layers of alloy including about 80% nickel and 20% iron content, etc.) along respective first and second opposite sides of the first electrically conductive layer. Third and fourth permalloy layers (e.g., third and fourth layers including about 80% nickel and 20% iron content, etc.) are along respective third and fourth opposite sides of the second electrically conductive layer. An electromagnetic noise suppression layer (e.g., a magnetically conductive metal layer, an electrically conductive metal layer, or an electromagnetic noise absorbing elastomer layer, etc.) is sandwiched between the second and third permalloy layers.

As compared to conventional electromagnetic shielding films, exemplary embodiments of the electromagnetic energy mitigation assemblies disclosed herein may advantageously be configured to have good and/or improved shielding effectiveness greater than 20 decibels (e.g., 30 decibels, etc.) at frequencies within a range from 10 kilohertz to 30 kilohertz (e.g., a shielding effectiveness of at least 38 decibels at a frequency of 30 kilohertz, a shielding effectiveness as shown inFIG.3, etc.) and or to have good and/or reduced softness (e.g.,FIG.4, etc.).

With reference now to the figures,FIG.1illustrates an electromagnetic energy mitigation assembly100(e.g., an electromagnetic shielding film or multilayer structure, etc.) according to an exemplary embodiment. As shown, the electromagnetic energy mitigation assembly100includes a first electrically conductive layer104. First and second permalloy layers108,112are along (e.g., coated, plated, deposited, applied thereon without using an adhesive, etc.) respective first and second opposite sides of the first electrically conductive layer104. The electromagnetic energy mitigation assembly200also includes a second electrically conductive layer116. Third and fourth permalloy layers120,124are along (e.g., coated, plated, deposited, applied thereon without using an adhesive, etc.) respective third and fourth opposite sides of the second electrically conductive layer116. The electromagnetic energy mitigation assembly100further includes an electromagnetic noise suppression layer128sandwiched between (e.g., adhesively bonded or attached to, etc.) the second and third permalloy layers112,120.

The first electrically conductive layer104may comprise an electrically conductive metal layer, such as copper, aluminum, stainless steel, or other suitable electrically conductive layer. By way of example, the first electrically conductive layer104comprises a first copper foil. And the first and second permalloy layers108,112comprise layers of alloy including about 80% nickel and 20% iron content that are respectively disposed along the respective first and second opposite sides of the first copper foil. The first copper foil and the first and second permalloy layers108,112may have a combined thickness within a range from 2 micrometers to 60 micrometers. For example, the first copper foil and the first and second permalloy layers108,112may have a combined thickness of about 20 micrometers in an exemplary embodiment. As another example, the first and second permalloy layers108,112may comprise layers of permalloy 80 or highly magnetic nickel-iron-molybdenum alloy that includes about 80% nickel, 15% iron, and 5% molybdenum content. As a further example, the first and second permalloy layers108,112may comprise layers of mu-metal.

The second electrically conductive layer116may comprise an electrically conductive metal layer, such as copper, aluminum, stainless steel, or other suitable electrically conductive layer. By way of example, the second electrically conductive layer116comprises a second copper foil. And the third and fourth permalloy layers120,124may comprise layers of alloy including about 80% nickel and 20% iron content that are respectively disposed along the respective first and second opposite sides of the second copper foil. The second copper foil and the third and fourth permalloy layers120,124may have a combined thickness within a range from 2 micrometers to 60 micrometers. For example, the second copper foil and the third and fourth permalloy layers120,124may have a combined thickness of about 20 micrometers in an exemplary embodiment. As another example, the third and fourth permalloy layers120,124may comprise layers of permalloy 80 or highly magnetic nickel-iron-molybdenum alloy that includes about 80% nickel, 15% iron, and 5% molybdenum content. As a further example, the third and fourth permalloy layers120,124may comprise layers of mu-metal.

The electromagnetic noise suppression layer128may comprise a magnetically conductive metal layer, an electrically conductive metal layer, an electromagnetic noise absorbing elastomer layer, other electromagnetic wave absorbing material sandwiched between (e.g., adhesively bonded or attached to, etc.) the second and third permalloy layers112,120. By way of example, the electromagnetic noise suppression layer128may comprise an electromagnetic noise absorbing elastomer layer (e.g., magnetic powder within resin, etc.) having one or more of the properties shown in Table 1 below. The electromagnetic noise suppression layer128may have a thickness within a range from 0.03 millimeters to 1 millimeter. For example, the electromagnetic noise suppression layer128may have a thickness of about 0.2 millimeters.

With continued reference toFIG.1, the first permalloy layer108defines an outermost top surface of the electromagnetic energy mitigation assembly100. The fourth permalloy layer124defines an outermost bottom surface of the electromagnetic energy mitigation assembly100. The electromagnetic energy mitigation assembly100may comprise a multilayer electromagnetic shielding sheet or film.

In exemplary embodiments, an automotive vehicle component comprises the electromagnetic energy mitigation assembly100. The electromagnetic energy mitigation assembly100is configured to define or be positionable along a surface above one or more batteries of an automotive vehicle whereat the electromagnetic energy mitigation assembly is operable for providing electromagnetic shielding for the one or more batteries. In an exemplary embodiment, the electromagnetic energy mitigation assembly100may be positionable within the automotive vehicle to define a thermally-conductive heat transfer path for thermal management, e.g., for the one or more batteries, etc.

In exemplary embodiments, an automotive vehicle comprises the electromagnetic energy mitigation assembly100. And the electromagnetic energy mitigation assembly100is positioned relative to one or more batteries of the automotive vehicle such that the electromagnetic energy mitigation assembly is operable for providing electromagnetic shielding for the one or more batteries. In an exemplary embodiment, the electromagnetic energy mitigation assembly100is positioned within the automotive vehicle to define a thermally-conductive heat transfer path for thermal management, e.g., for the one or more batteries, etc.

FIG.3includes a line graph of shielding effectiveness in decibels (dB) versus frequency in hertz (Hz) for a prototype of the electromagnetic energy mitigation assembly100according to the exemplary embodiment shown inFIG.1where the shielding effectiveness testing included using magnetic loop antennas.FIG.4includes a line graph of force in Newtons (N) versus deflection in millimeters (mm) for a prototype of an electromagnetic energy mitigation assembly according to the exemplary embodiment shown inFIG.1using the setup/fixture shown inFIG.4to gauge or predict softness. For this deflection/softness testing, the less force required to deflect a first sample to a same thickness as a second sample indicates that the first sample is softer than the second sample.

For the shielding effectiveness testing shown inFIG.3and the deflection/softness testing shown inFIG.4, the prototype of the electromagnetic energy mitigation assembly100included the following. The first electrically conductive layer104comprised a first copper foil. The first and second permalloy layers108,112comprised layers of alloy including about 80% nickel and 20% iron content respectively disposed along the respective first and second opposite sides of the first copper foil. The first copper foil and the first and second permalloy layers108,112had a combined thickness of about 20 micrometers. The second electrically conductive layer116comprised a second copper foil. The third and fourth permalloy layers120,124comprised layers of alloy including about 80% nickel and 20% iron content respectively disposed along the respective first and second opposite sides of the second copper foil. The second copper foil and the third and fourth permalloy layers120,124had a combined thickness of about 20 micrometers in an exemplary embodiment. The electromagnetic noise suppression layer128comprised an electromagnetic noise absorbing elastomer layer having the properties shown in Table 1 above. The electromagnetic noise suppression layer128had a thickness of about 0.2 millimeters.

As shown byFIG.3, the prototype of the electromagnetic energy mitigation assembly100had a shielding effectiveness greater than 20 decibels at frequencies within a range from 10 kilohertz to 30 kilohertz. For example, the prototype of the electromagnetic energy mitigation assembly100had a shielding effectiveness of at least 38 decibels at a frequency of 30 kilohertz.

As shown byFIG.4, the prototype of the electromagnetic energy mitigation assembly100was also relatively soft. For example, the prototype of the electromagnetic energy mitigation assembly100having a length of 70 millimeters and width of 1 millimeter deflected at least 8 millimeters at a force less than 2 Newtons.

FIG.2illustrates another electromagnetic energy mitigation assembly200(e.g., an electromagnetic shielding film or multilayer structure, etc.) according to another exemplary embodiment. As shown, the electromagnetic energy mitigation assembly200includes an electrically conductive layer204. First and second permalloy layers208,212are along (e.g., coated, plated, deposited, applied thereon without using an adhesive, etc.) respective first and second opposite sides of the electrically conductive layer204.

The electrically conductive layer204may comprise an electrically conductive metal layer, such as copper, aluminum, stainless steel, or other suitable electrically conductive layer. By way of example, the electrically conductive layer204comprises a copper foil. And the first and second permalloy layers208,212comprise alloy layers including about 80% nickel and 20% iron content that are respectively disposed along the respective first and second opposite sides of the copper foil. The copper foil and the first and second permalloy layers208,212may have a combined thickness within a range from 2 micrometers to 60 micrometers. For example, the copper foil and the first and second permalloy layers208,212may have a combined thickness of about 20 micrometers in an exemplary embodiment. As another example, the first and second permalloy layers208,212may comprise layers of permalloy 80 or highly magnetic nickel-iron-molybdenum alloy that includes about 80% nickel, 15% iron, and 5% molybdenum content. As a further example, the first and second permalloy layers208,212may comprise layers of mu-metal.

With continued reference toFIG.2, the first permalloy layer208defines an outermost top surface of the electromagnetic energy mitigation assembly200. The second permalloy layer212defines an outermost bottom surface of the electromagnetic energy mitigation assembly200. The electromagnetic energy mitigation assembly200may comprise a multilayer electromagnetic shielding sheet or film.

In exemplary embodiments, an automotive vehicle component comprises the electromagnetic energy mitigation assembly200. The electromagnetic energy mitigation assembly200is configured to define or be positionable along a surface above one or more batteries of an automotive vehicle whereat the electromagnetic energy mitigation assembly is operable for providing electromagnetic shielding for the one or more batteries. In an exemplary embodiment, the electromagnetic energy mitigation assembly200may be positionable within the automotive vehicle to define a thermally-conductive heat transfer path for thermal management, e.g., for the one or more batteries, etc.

In exemplary embodiments, an automotive vehicle comprises the electromagnetic energy mitigation assembly200. And the electromagnetic energy mitigation assembly200is positioned relative to one or more batteries of the automotive vehicle such that the electromagnetic energy mitigation assembly is operable for providing electromagnetic shielding for the one or more batteries. In an exemplary embodiment, the electromagnetic energy mitigation assembly200is positioned within the automotive vehicle to define a thermally-conductive heat transfer path for thermal management, e.g., for the one or more batteries, etc.

Accordingly, exemplary embodiments are disclosed of electromagnetic energy mitigation assemblies. In an exemplary embodiment, 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.

In exemplary embodiments, the first and second electrically conductive layers comprise first and second copper layers, respectively. And the electromagnetic noise suppression layer comprises a magnetically conductive metal layer, an electrically conductive metal layer, or an electromagnetic noise absorbing elastomer layer.

In exemplary embodiments, the electromagnetic noise suppression layer comprises an electromagnetic noise absorbing elastomer layer.

In exemplary embodiments, the first and fourth permalloy layers define outermost surfaces of the electromagnetic energy mitigation assembly.

In exemplary embodiments, the first electrically conductive layer and the first and second permalloy layers have a combined thickness within a range from 2 micrometers to 60 micrometers. The second electrically conductive layer and the third and fourth permalloy layers have a combined thickness within a range from 2 micrometers to 60 micrometers. And the electromagnetic noise suppression layer has a thickness within a range from 0.03 millimeters to 1 millimeter.

In exemplary embodiments, the first electrically conductive layer and the first and second permalloy layers have a combined thickness of 20 micrometers. The second electrically conductive layer and the third and fourth permalloy layers have a combined thickness of 20 micrometers. And the electromagnetic noise suppression layer has a thickness of 0.2 millimeters.

In exemplary embodiments, the electromagnetic energy mitigation assembly is configured to have a shielding effectiveness greater than 20 decibels at frequencies within a range from 10 kilohertz to 30 kilohertz. For example, the electromagnetic energy mitigation assembly may be configured to have a shielding effectiveness of at least 38 decibels at a frequency of 30 kilohertz.

In exemplary embodiments, the first and second permalloy layers comprise first and second permalloy coatings along the respective first and second opposite sides of the first electrically conductive layer. And the third and fourth permalloy layers comprise third and fourth permalloy coatings along the respective third and fourth opposite sides of the second electrically conductive layer.

In exemplary embodiments, the first and second permalloy layers comprise first and second permalloy platings along the respective first and second opposite sides of the first electrically conductive layer. And the third and fourth permalloy layers comprise third and fourth permalloy platings along the respective third and fourth opposite sides of the second electrically conductive layer.

In exemplary embodiments, the first and second permalloy layers comprise first and second nickel-iron magnetic alloy deposits along the respective first and second opposite sides of the first electrically conductive layer. And the third and fourth permalloy layers comprise third and fourth nickel-iron magnetic alloy deposits along the respective third and fourth opposite sides of the second electrically conductive layer.

In exemplary embodiments, the electromagnetic energy mitigation assembly consists of only: the first and second permalloy layers along the respective first and second opposite sides of the first electrically conductive layer; the third and fourth permalloy layers along the respective third and fourth opposite sides of the second electrically conductive layer; and the electromagnetic noise suppression layer adhesively bonded between the second and third permalloy layers.

In exemplary embodiments, the electromagnetic energy mitigation assembly consists of only: a first multilayer structure defined by or including the first and second permalloy layers along the respective first and second opposite sides of the first electrically conductive layer; a second multilayer structure defined by or including the third and fourth permalloy layers along the respective third and fourth opposite sides of the second electrically conductive layer; and the electromagnetic noise suppression layer adhesively bonded between the first multilayer structure and the second multilayer structure, the electromagnetic noise suppression layer softer than the first multilayer structure and the second multilayer structure.

In exemplary embodiments, the first electrically conductive layer comprises a first copper foil. The first and second permalloy layers are disposed along respective first and second opposite sides of the first copper foil such that the first copper foil and the first and second permalloy layers have a combined thickness within a range from 2 micrometers to 60 micrometers. The second electrically conductive layer comprises a second copper foil. The third and fourth permalloy layers are disposed along respective third and fourth opposite sides of the second copper foil such that the second copper foil and the third and fourth permalloy layers have a combined thickness within a range from 2 micrometers to 60 micrometers. The electromagnetic noise suppression layer comprises an electromagnetic noise absorbing elastomer layer having a thickness from 0.03 millimeters to 1 millimeter. And the electromagnetic energy mitigation assembly is configured to have a shielding effectiveness greater than 20 decibels at frequencies within a range from 10 kilohertz to 30 kilohertz.

In exemplary embodiments, the electromagnetic energy mitigation assembly is a multilayer electromagnetic shielding sheet or film.

In exemplary embodiments, an automotive vehicle component comprises an electromagnetic energy mitigation assembly as disclosed herein. The electromagnetic energy mitigation assembly is configured to define or be positionable along a surface above one or more batteries of an automotive vehicle whereat the electromagnetic energy mitigation assembly is operable for providing electromagnetic shielding for the one or more batteries.

In exemplary embodiments, an automotive vehicle comprises an electromagnetic energy mitigation assembly as disclosed herein. The electromagnetic energy mitigation assembly is positioned relative to one or more batteries of the automotive vehicle such that the electromagnetic energy mitigation assembly is operable for providing electromagnetic shielding for the one or more batteries.

Also disclosed are exemplary embodiments of automotive vehicle components including electromagnetic energy mitigation assemblies. In an exemplary embodiment, 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.

In exemplary embodiments of the automotive vehicle component, the electromagnetic energy mitigation assembly further comprises: a second electrically conductive layer; third and fourth permalloy layers along respective third and fourth opposite sides of the second electrically conductive layer; and an electromagnetic noise suppression layer sandwiched between the second and third permalloy layers. The first and second electrically conductive layers may comprise first and second copper layers, respectively. And the electromagnetic noise suppression layer may comprises a magnetically conductive metal layer, an electrically conductive metal layer, or an electromagnetic noise absorbing elastomer layer.

In exemplary embodiments of the automotive vehicle component, the electromagnetic energy mitigation assembly comprises an electromagnetic noise absorbing elastomer layer.

In exemplary embodiments of the automotive vehicle component, the electromagnetic energy mitigation assembly the first and second permalloy layers respectively define outermost surfaces of the electromagnetic energy mitigation assembly.

In exemplary embodiments of the automotive vehicle component, the first electrically conductive layer comprises a first copper foil. And the first and second permalloy layers are disposed along respective first and second opposite sides of the first copper foil such that the first copper foil and the first and second permalloy layers have a combined thickness within a range from 2 micrometers to 60 micrometers.

In exemplary embodiments of the automotive vehicle component, the electromagnetic energy mitigation assembly is a multilayer electromagnetic shielding sheet or film.

In exemplary embodiments, an automotive vehicle comprises an automotive vehicle component including an electromagnetic energy mitigation assembly as disclosed herein. The electromagnetic energy mitigation assembly is positioned relative to one or more batteries of the automotive vehicle such that the electromagnetic energy mitigation assembly is operable for providing electromagnetic shielding for the one or more batteries.

The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally”, “about”, and “substantially” may be used herein to mean within manufacturing tolerances.