Durable EMI/RFI shield between two or more structural surfaces and shield formed therefrom

• US 7,307,223 B2
• Filed: 06/01/2006
• Issued: 12/11/2007
• Est. Priority Date: 02/08/2002
• Status: Expired due to Fees

• Current Assignee: Deborah S. Tyson, Kenneth E. Tyson
• Original Assignee: Proteus Technical Solutions, Inc.
• Inventors: Marzan, Theodore, Tyson, Deborah S., Walker, Ronald B., Tyson, Kenneth E.
• Primary Examiner(s): Ngo; Hung V.
• Application Number:
  US11/446,442
• Publication Number:
  US 20070062731A1
• Time in Patent Office: 558 Days
• Field of Search: 174/377, 174/371, 174/372
• US Class Current: 174/372
• CPC Class Codes: H05K 9/0088 comprising a plurality of shielding layers; combining different shielding material structure

Abstract

A method for producing a durable electromagnetic and radio frequency interference shield between two or more structural members of a wall or enclosure and a shielded shelter produced using the method. In one embodiment, joints between structural members are preferably filled with an electrically conductive filler. A base coat of a metal spray that adheres well to the filler and structural member is then applied. At least one layer of a metal spray with magnetic field attenuation properties such as steel, and at least one layer of a metal spray that has plane wave attenuation properties such as tin are applied to the base coat. Optionally, a coat of protective or conductive paint is then applied to the top surface of the metal spray layers. An enclosure with shielded joints according to the present invention has superior shielding capability and durability over the art.

Claims

1. A shield to electromagnetic and radio frequency interference, comprising:

a plurality of base structural members joined to at least one other base structural member;

a filler disposed in irregularities and joints between said base structural members;

a bond coat of a conductive metal spray over said base structural members;

a first coat of a conductive metal spray over said bond coat; and

a second coat of a conductive metal spray over said first coat of conductive metal spray.

2. A shield as recited in claim 1, wherein said filler comprises electrically conductive filler.

3. A shield as recited in claim 2, wherein said electrically conductive filler comprises a metal particulate impregnated epoxy.

4. A shield as recited in claim 3, wherein metal particulates of said metal particulate impregnated epoxy comprise particulates of at least two different metals.

5. A shield as recited in claim 1, wherein said bond coat of conductive metal spray comprises molybdenum with a thickness of between approximately 2 millimeters to approximately 3 millimeters.

6. A shield as recited in claim 1, wherein said bond coat of conductive metal spray comprises a molybdenum alloy with a thickness of between approximately 2 millimeters to approximately 3 millimeters.

7. A shield as recited in claim 1, wherein said first coat of conductive metal spray comprises steel metal spray with a thickness of between approximately 2 millimeters to approximately 10 millimeters.

8. A shield as recited in claim 1, wherein said first coat of conductive metal spray comprises iron metal spray with a thickness of between approximately 2 millimeters to approximately 10 millimeters.

9. A shield as recited in claim 1, wherein said second coat of conductive metal spray comprises tin with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

10. A shield as recited in claim 1, wherein said second coat of conductive metal spray comprises a tin alloy with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

11. A shield as recited in claim 1, wherein said second coat of conductive metal spray comprises tin and zinc metal spray having an approximate 8:

2 ratio of tin to zinc and a thickness of between approximately 2 millimeters to approximately 80 millimeters.

12. A shield as recited in claim 1, further comprising:

a third coat of a conductive metal spray disposed on said coat of a second conductive metal spray.

13. A shield as recited in claim 12, wherein said first coat of conductive metal spray comprises tin with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

14. A shield as recited in claim 12, wherein said third coat of conductive metal spray comprises a tin alloy with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

15. A shield as recited in claim 12, wherein said first coat of conductive metal spray comprises tin and zinc metal spray having an approximate 8:

2 ratio of tin to zinc and a thickness of between approximately 2 millimeters to approximately 80 millimeters.

16. A shield as recited in claim 12, wherein said second coat of conductive metal spray comprises steel metal spray with a thickness of between approximately 2 millimeters to approximately 10 millimeters.

17. A shield as recited in claim 12, wherein said second coat of conductive metal spray comprises iron metal spray with a thickness of between approximately 2 millimeters to approximately 10 millimeters.

18. A shield as recited in claim 12, wherein said third coat of conductive metal spray comprises tin with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

19. A shield as recited in claim 12, wherein said third coat of conductive metal spray comprises a tin alloy with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

20. A shield as recited in claim 12, wherein said third coat of conductive metal spray comprises tin and zinc metal spray having an 8:

2 ratio of tin to zinc and a thickness of between approximately 2 millimeters to approximately 80 millimeters.

21. An enclosure shielded to electromagnetic and radio frequency interference, comprising:

a top panel;

a bottom panel;

front, rear, left side and right side walls joined to said top panel and to said bottom panel said front and rear walls joined to said left and right walls configured to form an enclosure;

electrically conductive filler disposed within joints between said walls and said panels;

a plurality of layers of metal spray coating said panels, walls and filled joints adapted to provide resistance to electromagnetic interference; and

a coating of paint to a top layer of metal spray;

wherein said coating of paint comprises a conductive paint.

22. An enclosure shielded to electromagnetic and radio frequency interference, comprising:

a top panel;

a bottom panel;

front, rear, left side and right side walls joined to said top panel and to said bottom panel said front and rear walls joined to said left and right walls configured to form an enclosure;

electrically conductive filler disposed within joints between said walls and said panels; and

a plurality of layers of metal spray coating said panels, walls and filled joints adapted to provide resistance to electromagnetic interference;

wherein said electrically conductive filler comprises a metal impregnated epoxy.

23. A shield as recited in claim 22, wherein said metal of said metal impregnated epoxy comprises steel particulates.

24. An enclosure shielded to electromagnetic and radio frequency interference;

comprising;

a top panel;

a bottom panel;

front, rear, left side and right side walls joined to said top panel and to said bottom panel said front and rear walls joined to said left and right walls configured to form an enclosure;

electrically conductive filler disposed within joints between said walls and said panels;

a plurality of layers of metal spray coating said panels, walls and filled joints adapted to provide resistance to electromagnetic interference; and

a coating of paint to a top layer of metal spray;

wherein said coating of paint comprises an elastomeric coating.

25. An enclosure shielded to electromagnetic and radio frequency interference, comprising:

a top panel;

a bottom panel;

front, rear, left side and right side walls joined to said top panel and to said bottom panel said front and rear walls joined to said left and right walls configured to form an enclosure;

electrically conductive filler disposed within joints between said walls and said panels; and

a plurality of layers of metal spray coating said panels, walls and filled joints adapted to provide resistance to electromagnetic interference;

wherein said layers of metal spray comprise;

a base coat of conductive metal spray;

a first coat of a conductive metal spray; and

a second coat of conductive metal spray.

26. An enclosure as recited in claim 25, wherein said base coat of conductive metal comprises molybdenum with a thickness of between approximately 2 millimeters to approximately 3 millimeters.

27. An enclosure as recited in claim 25, wherein said first coat of conductive metal spray comprises steel metal spray with a thickness of between approximately 2 millimeters to approximately 10 millimeters.

28. An enclosure as recited in claim 25, wherein said second coat of conductive metal spray comprises tin with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

29. An enclosure as recited in claim 25, wherein said second coat of conductive metal spray comprises tin and zinc metal spray having an 8:

2 ratio of tin to zinc and a thickness of between approximately 2 millimeters to approximately 80 millimeters.

30. An enclosure shielded to electromagnetic and radio frequency interference, comprising:

a top panel;

a bottom panel;

front, rear, left side and right side walls joined to said top panel and to said bottom panel said front and rear walls joined to said left and right walls configured to form an enclosure;

electrically conductive filler disposed within joints between said walls and said panels; and

a plurality of layers of metal spray coating said panels, walls and filled joints adapted to provide resistance to electromagnetic interference;

wherein said layers of metal spray comprise;

a base coat of conductive metal spray;

a first coat of a conductive metal spray;

a second coat of conductive metal spray; and

a third coat of conductive metal spray.

31. An enclosure as recited in claim 30, wherein said base coat of conductive metal comprises molybdenum with a thickness of between approximately 2 millimeters to approximately 3 millimeters.

32. An enclosure as recited in claim 30, wherein said base coat of conductive metal comprises a molybdenum alloy with a thickness of between approximately 2 millimeters to approximately 3 millimeters.

33. An enclosure as recited in claim 30, wherein said first coat of conductive metal spray comprises approximately tin with a thickness of between approximately 2 millimeters to approximately 10 millimeters.

34. An enclosure as recited in claim 30, wherein said first coat of conductive metal spray comprises tin and zinc metal spray having an 8:

2 ratio of tin to zinc and a thickness of between approximately 2 millimeters to approximately 10 millimeters.

35. An enclosure as recited in claim 30, wherein said second coat of conductive metal spray comprises steel metal spray with a thickness of between approximately 2 millimeters to approximately 10 millimeters.

36. An enclosure as recited in claim 30, wherein said third coat of conductive metal spray comprises approximately 99% pure tin with a thickness of between approximately 2 millimeters to approximately 80 millimeters.

37. An enclosure as recited in claim 30, wherein said third coat of conductive metal spray comprises tin and zinc metal spray having an 8:

2 ratio of tin to zinc and a thickness of between approximately 2 millimeters to approximately 80 millimeters.