Multifunctional Lightweight Electromagnetically Shielded Enclosure Technology Using Affordable Hybrid Carbon Composite Production Processes

The objective of this proposal is to establish a robust EMI coating and shielding methodology integrated onto an advanced hybrid composite electronic enclosure. The hybrid enclosure utilizes a hybrid of high thermal conductivity graphite fibers/foams, structural composite fibers, and metallic materials. The proposed activity herein will promote novel EMI coatings combined with pitch-based thermally conductive graphite fiber composites. Properties of candidate fibers typically range from less than 3.0 micro ohm-m in electrical resistance with thermal performance exceeding 500 W/mK. The Phase 1 effort will integrate and demonstrate a cost effective EMI coating solution that is partnered with the aforementioned pitch based composite materials. The proposed solution will meet the requirements associated with electromagnetic environmental effects (EEE), shielding, corrosion resistance, and allow for maximum thermal performance. In terms of EMI shielding and ESD grounding of the hybrid enclosure, performance is expected to meet or exceed that of the current aluminum chassis baseline design. Key technologies including coatings, materials, and processes will be demonstrated in Phase 1. The application of EMI coatings will apply to a wide array of DOD and commercial applications. This opportunity will lead to manufacture of a qualifiable working enclosure in Phase 2.