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Engineering Materials

Putting the safety into EMI shielding with Xytron™ PPS

Electrical drivetrains are crucial to combat global warming, but there is a challenge to overcome—high voltage electrical powertrains generate electrical magnetic interference (EMI), which impacts the critical electronics needed to realize connected and autonomous vehicles. 

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Currently, the most used options for EMI shielding are metal covers, metalized plastic covers, standard plastic with metal sheet/foil, conductive plastic covers and carbon fiber composite structures. Although prominent, they have drawbacks that can lead to reliability risks, higher weight or assembly costs.

For instance if the shield is not reliable, EMI can cause system-malfunction, and even failure. Consequence of system interference can be dangerous—there have been reports of airbags deploying, triggered by emergency service vehicle RF transmissions and engine management, and cruise control systems demanding ‘full throttle’ when subjected to EMI. 

Balancing conductivity and good mechanics

To ensure reliability during vehicle operation, the proper shielding of emitters is necessary. It has been found that 40-50dB shielding is sufficient for almost all EMI shielding applications, and that performance differentiation is achieved via sophisticated interface science polymer/fillers.

When designing with conductive material solutions, there are several advantages:

  • Design freedom – sleek design with high flexibility, improving overall efficacy of the module, EMI shielding and thermal conduction 
  • Lower weight – up to 50% weight reduction vs. Aluminum
  • High productivity – lower energy consumption and longer tool life as compared to Aluminum
  • No secondary finishing processes (drilling, sanding, painting, etc.)
  • Inherent corrosion/oxidation resistance
  • Increased reliability (no delamination of paints or coatings)
  • Total cost reduction vs. machined metal components

DSM’s XytronTM PPS offers best in class shielding carbon fibre (CF) composites with the highest shielding levels, thermal conductivity and good mechanics. Composites reduce wall thicknesses by four times and increase the conductivity to metal levels.

At DSM, we support our customers and help them win in powertrain electrification by offering an advanced material solution, along with design support for metal replacement.

To learn more contact us or visit Plastics Finder.  

Dr. Tamim Peter Sidiki

Global Marketing Manager of Mobility

Published on

04 March 2021

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ABOUT THE AUTHOR

Dr. Tamim Peter Sidiki

Global Marketing Manager of Mobility

Dr. Tamim Peter Sidiki is Global Marketing Manager of Mobility. Tamim holds a Master Degree in Physics and a Ph.D. in Electrical Engineering obtained at Universities in Germany, Sweden and Scotland. Tamim has more than 20 years of experience in the consumer and automotive electronics industry and has been with DSM since October 2007.

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