Automotive manufacturers are constantly developing new technologies to improve the performance, durability and safety of passenger vehicles and commercial transport. The growing evolution of electric vehicles (EVs) in a low-carbon economy means manufacturers in this industry need reliable and sustainable partners within the supply chain.
Polymer Science has placed a significant amount of engineering research and development into helping manufacturers of electric vehicles with P-SHIELD® Shielding & Grounding Materials, P-THERM® Thermal Interface Materials, and general-purpose materials.
Reducing Electromagnetic Interference in EV Applications
Polymer Science’s EMI shielding & grounding materials protect electronic components from electromagnetic interference (EMI) to ensure electronic components function optimally. Within EV applications, our wide range of materials helps with safe function and improving overall performance. Our lightweight and effective materials are used in battery management systems, motor controllers, power electronics and in cabin displays.
One of the sources of potential electromagnetic interference in an electric vehicle is the power converter. The power converter uses high-speed switching devices.
Sources of EMI Interference
When you think about an electric vehicle, thermal management and cooling the vehicle are the first things that come to mind; however, you should also be considering shielding and grounding materials as well. There are several sources of potential electromagnetic interference, or EMI, in an electric vehicle.
The primary source of EMI in an electric vehicle is the power converter. When converting DC power stored in the battery to AC power required to drive the electric motor, the power converter systems use high-speed switching devices to work at high frequencies over a wide frequency range which can generate harmonics. This interference can lead to reduced efficiency, lower performance and safety risks.
EM noise can be created when the EV’s drive motor is in operation. Other sources of interference can occur in the batteries, the charging ports on the vehicle and the charging stations. Cutting-edge technology within the cabin of the vehicle also needs effective EMI Shielding & Grounding. Navigation & infotainment systems house electronic systems in compact designs. Within an electric vehicle, there are multiple systems operating within a confined space. Using the correct EMI Shielding & Grounding solutions is extremely important in EV design and manufacturing.
Polymer Science offers conductive tapes, adhesives, fabrics, foils and foams for EMI Shielding & Grounding in electric vehicles. Some examples include:
P-SHIELD® Shielding & Grounding Materials
- Fabric Tape: Crafted using highly durable materials, conductive fabric tapes are perfect for dynamic applications. In addition, the exceptional flexibility of these tapes enable them to be used within housings and cables with ease. Designed to cater to the needs of modern-day engineers, P-SHIELD® fabric tapes have a lightweight and thin profile that makes them ideal for compact designs where space is at a premium.
- Conductive Adhesives: The electric vehicle industry is driving a more sustainable manufacturing process. Conductive adhesives provide an eco-friendly option in adhesives that lower production costs and increase durability within strong prone systems. Polymer Science’s P-SHIELD® adhesives also have the ability to bond and shield sensitive components.
- Additional materials: Foam tape, foil tape, conductive fabrics and conductive foams all offer unique benefits for EMI Shielding and grounding.
Thermal Management in EV Applications
Thermal management is critical to the performance and safety of electric vehicles. Polymer Science’s P-THERM® Thermal Management Materials are used in various EV applications including battery cooling systems, within the battery pack and between individual cells. Within the cabin, the compact designs of navigation & infotainment systems also benefit from our thermal management materials. Wherever heat is produced, thermal management materials can improve performance and safety.
P-THERM® Thermal Management Materials
Our thermal management materials are designed to dissipate heat and maintain the optimal operating temperature of different EV components. They provide effective heat transfer, ensuring that the components do not overheat and fail. When the battery charges and discharges, heat is produced. Effective thermal management protects components and helps to increase performance. Optimal conditions help EV batteries hold a longer charge. Lightweight materials reduce overall vehicle weight which help increase performance as well.
Polymer Science offers gap fillers, phase change materials, heat spreaders and adhesives within our thermal management product line. Our wide range of solutions help manufacturers with many challenges.
- Two Part Dispensables: A common gap filler provides secure and durable bonding between battery cells, the battery pack and the cooling system within EV batteries. P-THERM® Materials can be applied with precision, reducing material waste and lowering the weight compared to solid gap fillers.
Working with Polymer Science
Whatever problem you experience, Polymer Science is eager to work with EV manufacturers. Our talented team has a long history of helping cutting-edge manufacturers in automotive, computers, smartphones and other industries. We draw on our knowledge and track record to help new partners innovate in EV design.