Freudenberg's new approach to protective shields for electric cars makes use of nonwovens

WEINHEIM, Germany, April 8, 2019-

Electronic components must be protected from disruptions caused by electromagnetic waves. Experts from Freudenberg Performance Materials and Freudenberg Sealing Technologies are working together on ways to provide shielding with plastic housings. In the future, they could partially replace the aluminum versions that have dominated the market until now.

Fields of electromagnetic interference often form where electric current flows. When the flow is powerful, in high-performance electric powertrains, for example, the strength of these fields increases, and they can disrupt the signal flow in microprocessors and transmitter-receiver systems. One proven remedy is the encasement of electric components in housings made of a conductive metal. So far, aluminum has been the main tried-and-tested material for this. But its use substantially increases the proportion of aluminum in electric vehicles. This doesn’t just impair driving dynamics and vehicle range. Costs also rise because the tools used to produce the aluminum housings have limited durability. Due to their lack of conductivity, significantly lighter plastics have not been considered as materials so far. But experts from Freudenberg Performance Materials and Freudenberg Sealing Technologies have teamed up to develop processes that can equip plastics with conductive coatings or nonwovens. Early lab tests show excellent values for electromagnetic shielding: up to 99.999999 percent.

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