Modern electrical systems need EMI shielding without the extra weight
Electromagnetic interactions (EMI) are a serious challenge for electrical systems. Our increasing reliance on automated electronic systems coupled with growing electromagnetic "pollution" in the environment demands a fresh take. Aerospace and defense designers and engineers must produce products that effectively shielding sensitive electronic equipment from EMI without adding significant weight. Galvorn offers a promising solution for EMI shielding and lightweighting.
Lightweight CNT braid can replace heavy metal braids
Current commercial of-the-shelf-versions of these cables use copper braid as outer conductors. DexMat produced lightweight coaxial cables shielded with Galvorn carbon nanotube (CNT) braids. These CNT-based shielding components replaced heavy metal braids. The results included excellent shielding effectiveness (SE) and insertion loss (IL) performance, as well as significant weight savings.
Key Results
- Produced CNT shielded cable. The insertion loss of this cable met military specifications and the shielding effectiveness was comparable to a COTS cable.
- The CNT cable (including inner conductor, dielectric, shield, and insulating jacket) was over 50 % lighter than the COTs cable.
SBIR Award: Robust Lightweight CNT Wiring for Space Systems
Lightweight CNT film provides EMI shielding with superior flex endurance
Galvorn carbon nanotube film is highly is mechanically strong, lightweight and flexible. You can fold the carbon nanotube film around an insulated wire (i.e., cigarette-wrapped). This approach produces a shielded cable that meets Mil Specs for Insertion Loss and Shielding Effectiveness performance. The cable also has significant flexure endurance.
Key Results
- A thin CNT film of ~300 microns in thickness provided comparable EMI shielding effectiveness to existing standard cables.
- At frequencies below 3 Gz., Galvorn cable proved superior versus the use of double-braided metal shields.
- Galvorn carbon nanotube film is ~95% lighter than standard (double) metal braids used in typical cables.
- Compared to a double braided cable, a CNT Shielded cable would be ~60% lighter in weight
- Compared to a single braided cable, a CNT Shielded cable would be ~35% lighter in weight.
SBIR Awards:
- Lightweight CNT Shielded Cables for Space Applications Ph. I
- Lightweight CNT Shielded Cables for Space Applications Ph. II
CNT fiber core for strong, lightweight transmission cables
Prysmian is a world leader in cable manufacturing, energy solutions, telecom cables and systems. DexMat and Prysmian are co-developing new Aluminum Carbon Nanotube (ACNT) power cables.
The U.S. Department of Energy is funding the work though a $1.1 million grant. ACNT cables replace traditional steel or carbon fiber cores with Galvorn carbon nanotube fibers. Galvorn offers an exceptional combination of properties for this application:
- thermal conductivity
- electrical conductivity
- light weight
- breaking strength
- tensile strength
Galvorn cables could save $100K per mile
Using Galvorn minimizes the number of cable support towers needed and reduces the total cost to taxpayers. Food for thought: NREL estimates that the United States will need up to 91,000 miles of new inter-regional transmission lines by 2035. WIth savings of $100,000 per mile, the installation of 91,000 miles of new transmission lines, would result in a total savings of $9.1 billion. This figure does not include further savings derived from decreased line losses, enhanced reliability, and so on.
