Thin, Flexible Nanostructured Films for High-Temperature EMI Shielding

Electronic devices generate unintended electromagnetic waves (EMW) which interact with neighboring components in a phenomenon known as EMI. As integrated devices operate at higher speeds and in closer proximity, EMI substantially increases and results in erroneous signals, device malfunction, and hardware deterioration. Materials that shield against EMI by attenuating EMW need to both minimize unwanted emissions and shield components from external stray signals. Historically, metal shrouds have been the preferred solution to counter EMI; however, their weight, rigidity, and susceptibility to corrosion make them less suitable for size, weight, and power (SWaP)-sensitive applications, compact devices, and austere environments. At present, there is a growing demand for lightweight EMI shielding materials that can meet the evolving requirements of sophisticated military and commercial technologies. Here, Mainstream proposes a novel nanocomposite which represents a significant improvement over metal shrouds which are heavier and have lower flexibility, chemical resistance, and dimensional stability at high temperatures. In Phase I, Mainstream will produce uniform nanocomposite films and measure their physical and chemical properties. Then we will demonstrate the shielding effectiveness of our proposed nanomaterial composite. Finally, we will prepare a technical data package for Ph II testing and prototype development of our EMI shielding material. In Phase II, we will develop and test a comprehensive prototype design that meets agency sponsorÆs performance criteria and guarantees that the final product aligns with ongoing missile defense architecture and can be integrated with existing manufacturing processes. All work described in the Phase I and Phase II will be performed using state-of-the-art process equipment, characterization facilities, and shielded electronics laboratories housed at Mainstream Engineering. Furthermore, Mainstream will leverage our experience in commercial chemical and military systems development to provide a clear pathway to commercialization in Phase III. Approved for Public Release | 24-MDA-11906 (16 Sep 24)