Automotive manufacturers are continually pushing boundaries to enhance the performance, durability, and safety of passenger vehicles and light-duty trucks. As the automotive industry evolves to meet the demands of the next generation of vehicles, manufacturers and suppliers require reliable and sustainable partners within their supply chain.
Essential Materials in Automotive Design and Manufacturing
Polymer Science is dedicated to supporting automotive manufacturers in their pursuit of excellence. Our engineering research and development efforts have resulted in a range of innovative solutions, including P-SHIELD® Shielding & grounding materials, P-THERM® Thermal interface materials, and general-purpose adhesives, tapes and coating materials.
Polymer Science’s offerings empower automotive manufacturers to improve electronic component protection, mitigate electromagnetic interference (EMI), optimize thermal management, and enhance overall vehicle safety, performance and reliability. By collaborating with Polymer Science, manufacturers gain access to cutting-edge technologies and dependable solutions that drive innovation in the automotive industry.
Thermal Management in Automotive Systems
Optimal thermal management continues to be key to the successful performance and longevity of automotive systems. Polymer Science provides decades of experience working across multiple industries. Our P-THERM® gap fillers, heat spreaders, phase change materials and adhesives offer unique solutions.
The right materials help to optimize performance within automotive systems. A key example of how Polymer Science benefits cutting-edge automotive designs include:
Battery and Motor Cooling
Efficient cooling is vital for the longevity and performance of battery packs and electric motors in conventional automotive, hybrid and electric vehicles. Thermal management materials ensure optimal operation by preventing overheating and enhancing charging and discharging efficiency.
In the case of Polymer Science 2-part dispensable gap fillers, automotive manufacturers gain additional benefits. Dispensables offer thinner bond lines, use less material and create less waste. Within the manufacturing process, dispensables may benefit production and streamline efficiency. The reduced weight of these durable materials positively impacts the range of vehicles and the efficiency of electric motors.
Infotainment and Navigation Systems
Another example lies within the cabin of vehicles. Energy density has always been a challenge within the automotive industry and as consumers demand more technology, manufacturers must integrate advanced infotainment and navigation systems into modern vehicles.
As a leader in electronics, Polymer Science provides the automotive industry with materials that serve multiple functions. Silicone thermal gap fillers and dispensables dissipate heat so devices run continuously. These materials also help absorb the shocks and vibrations common along roadways. Protecting sensitive components is key to ensuring the longevity of displays and devices.
EMI Shielding & Grounding in Automotive Systems
Alongside thermal management, electromagnetic interference shielding & grounding is essential to the proper operation of infotainment and navigation systems as well as other devices within automotive designs.
Polymer Science P-SHIELD® conductive tapes, foams, and adhesives provide a range of solutions for EMI shielding and grounding. Within the cabin, the density of devices includes wireless communication systems such as radios, Wi-Fi, Bluetooth, and cellular connections. These systems emit electromagnetic signals that may interfere with other onboard electronic components or external devices.
As well as the in-cabin electronics, a few additional sources of EMI include:
- High-Speed Switching Devices – Power converters and motor controllers use high-speed switching devices to convert and regulate electrical power. The rapid switching of currents can generate EMI, causing interference with nearby electronic components and systems.
- Electric Motors – Hybrid vehicles and EVs use electric motors for propulsion. The operation of these motors generates electromagnetic noise, affecting nearby electronic systems and potentially causing performance issues.
- Charging System – Charging and discharging of the battery can create electromagnetic noise that might interfere with sensitive electronic components in the vehicle.
- Electronic Control Units (ECUs) – Managing various functions such as engine control, transmission control, and safety systems, ECUs must operate safely.
- On-Board Diagnostic (OBD) Systems – Modern vehicles feature OBD systems that monitor vehicle performance and emissions. These systems use sensors and electronic components that may be susceptible to EMI, impacting their accuracy and reliability.
To meet these requirements, automotive design frequently employs films, tapes, and adhesives. Polymer Science EMI shielding & grounding materials ensure optimal system performance and provide additional benefits.
Foam tapes provide cushioning, sealing and insulating properties. These qualities help protect sensitive components from vibrations, shocks, harsh environmental conditions, extreme temperatures and other adversity.
Fabric tapes conform to irregular surfaces and offer abrasion resistance. The flexibility and durability of the fabric is a common solution for cable management.
Conductive adhesives provide a pathway for electrical current and offer an alternative to solder or mechanical fasteners.
Foams provide cushioning and conform to irregular shapes within electronic housings protecting battery packs, sensors and other components.
General Adhesives and Coatings in Automotive Manufacturing
Throughout body exteriors, lighting systems, windows and doors, Polymer Science provides superior general industrial adhesives, foams and tapes.
General-purpose adhesives are essential for various bonding applications in automotive manufacturing, offering strong adhesion to diverse substrates and materials. These adhesives contribute significantly to the assembly and bonding of various automotive components.
Silicone foams are durable for sealing against water, temperature changes, and resisting chemicals. Noise dampening and vibration help to quiet cabins. Compressible foams can also protect components during assembly processes.
Carrier tapes safeguard components during assembly and aid the production process.
Contact Polymer Science
Since 1998, Polymer Science has worked with businesses of all sizes. From the simplest solutions to the ever-increasing demands of energy-dense technologies, Polymer Science has the expertise and experience to design and supply diverse materials for the automotive industry.
When you contact Polymer Science our process includes defining the project, design, verification of the materials to suit your project and finally, ongoing support. We are capable of quickly fulfilling orders or providing custom solutions.