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Transcript of Korporacja KGL S.A.kgl.pl/wp-content/uploads/2015/10/1-EMI-Shielding-webinar-18062014... · EMI...
www.kgl.pl
Korporacja KGL S.A.
przy współpracy z / in co-operation with
RTP Company
przedstawia / presents
Wykorzystanie tworzyw sztucznych tłumiących fale
elektromagnetyczne (EMI) w celu zmniejszenia masy
i poprawy efektywności projektowania.
Utilizing EMI Shielding Plastics
to Reduce Weight and Improve Designs
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
What is EMI?
• ElectroMagnetic Interference = EMI
• Emitted from a source or Received by a device
• Frequency range of 1 kHz to 10 GHz
• Faraday Cage Principle:
– Barrier that reflects or conducts signals to ground
• Shielding provides “Immunity”
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
EMI in Action
EMI shields protect sensitive devices from high frequency sources in the area.
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
EMI in Action
EMI shields protect sensitive devices from high frequency sources in the area.
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Controlling EMI
EMI Shielding is a function of 4 variables:
– Conductivity of the material
– Thickness of the material
– Frequency of the interference
– Distance between the source of the
interference and the shield
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
EMI Shielding Fillers
Electrically Conductive modifiers:
• Carbon Powder
• Carbon fiber
• Carbon Nanotubes
• Stainless steel fiber
• Nickel-coated carbon fiber
• Other metallic additives
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Stainless Steel Fiber – Minimal affect on neat
resin properties
– Neat resin shrinkage
– Good shielding
– Cost effective
– Colorable
Nickel Coated Carbon Fiber
– Properties similar to carbon fiber compounds
– High shielding performance
– Higher cost
– Less colorable
Key Additive Comparison
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• This process results in very long, oriented fibers
relative to a conventional compounding process
• Our oriented, long fibers create much better
shielding coverage in molded housings than
random, short fibers
• We optimize other properties through base polymer
The Long Fiber Product
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
The Long Fiber Compound
Optimized via “Cube Blends”
“A” Pellet – LF Product provides EMI shielding
“B” Pellet – Optimizes all other properties
(including: Shrinkage, Color, FR, Impact Resistance)
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
EMI Shielding Compounds
Cube Blends:
• Pre-blended mix of 2 different pellet types
(shielding + physical properties)
• Blending ratio is maintained through shipping
• Retain long fiber length/aspect ratio
• Evenly dispersed during injection molding process
• SS loading up to 20% by weight
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Shielding Effectiveness (SE)
• A reduction in energy level of an EMI wave
through reflection and absorption
• Varies with frequency
• Expressed in Decibels (dB)
• Attenuation – Analogous to shielding effectiveness
• Expressed as a % of original signal
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
SE vs. Attenuation
Shielding Effectiveness
Attenuation Comparative
Rating
20 dB 90% Minimal Shielding
40 dB 99% Average Shielding
60 dB 99.9% Good Shielding
80 dB 99.99% Excellent Shielding
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• ASTM D4935
• Direct measurement method
• Relative ranking of materials
• Frequency range of 300MHz to 1.5 GHz
• Fast & Repeatable
• Flat test specimen – min. 6” diameter
• Units = Decibels of SE
Coaxial Transmission Line Test
Spectrum
Analyzer/Tracking
Generator
Test specimen
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
30
50
70
90
110
300 700 1100 1500
SE, d
B
MHz
SE of SSF Composites
D %
C %
B %
A %
ASTM D4935 Typical Results
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Variables Affecting Performance
• Frequency of Interference
• Distance from the Source
– Near Field -- Distance < Wavelength/6
– Far Field -- Distance > Wavelength/6
• Characteristics of the Source
– High Current, Low Voltage -- High Magnetic Component (H)
– High Voltage, Low Current -- High Electric Component (E)
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• Metallic paint/metal coatings
– Traditional TV Cabinets
• Metal foil/screen
– Microwave ovens operate at 2.45 GHz (122 mm)
• Actual metal housing
• Polymer compound
– Increases design freedom, part consolidation
– Eliminates secondary operations & reduces part cost
EMI Shielding Methods
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Challenges In Automotive Sensors
• Weight reduction
• Consistent shielding and quality
• Low frequency shielding
• Thermal management
• Global manufacturing and tech. support
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Eliminate Conductive Paint
• Review of Conductive Paint:
– Durability (flaking and scratching)
– Potential thin spots in coating
– Yield fallout from masking operation
– Environmental considerations
– Additional process
– Additional supplier
– Added cost
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
EMI Compounds Conductive Paint Metal Parts
Design Compatibility Injection molding provides
maximum design flexibility Line of sight process
requires simple designs Forming and fabrication
methods limit designs
Secondary Operations None Required Masking and coating by
outside supplier De-burring, screw bosses,
plating, etc.
Consistency Uniform performance Difficult to measure
thickness uniformity Uniform performance
Grounding Ground from any surface Ground from coated surface
only Ground from any surface
Durability/ Reliability Integrated into compound Subject to scratching,
flaking, or delamination Inherent to material
Production Volume Easily Increased Problematic to increase Capital Intensive
Production Speed 1-Step Process Additional processing step
by secondary supplier Time and labor intensive
Special Handling None Required due to poor
damage tolerance None
Weight Light-weight Light-weight Heavy parts
Review of Shielding Options
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Evaluating EMI Shielding Options
• Volume resistance is key
specification parameter
• Part surface molds resin
rich so surface resistance
is misleading
• Shielding effectiveness
depends on filler loading
and thickness of housing
• Grounding from anywhere
on part minimizes system
EMI
• Surface resistance of inside is
key specification parameter
• Outside surface has no
conductivity
• Since conductive coating is
thin, volume resistance will be
dominated by insulative layer
• Shielding effectiveness
depends on conductivity of
coating and coating thickness
• Grounding only from inside
surface
• Conductivity is consistent
on inside or outside of
housing
• Volume resistance can be
measured
• Shielding effectiveness
depends on thickness of
metal
• Grounding from anywhere
on part
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• EMI 300 Series (PC)
– UL Listed: V-0 @ 1/16”
(1.5 mm)
– Stainless steel fiber
– Glass fiber
reinforcement
– Pre-colored
Combination of Properties
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Applications for EMI Plastics
• Housings
• Connectors
• Sensors
• Gaskets
• Wire and Cable
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Position Sensor Housings
• RTP 200 Series (PA66)
• Laser welding grade
• Natural cover is laser transparent
• Black body is laser absorbing
• Eliminated need for adhesive
• Increased quality
• Reduced system cost
Sensor Application Successes
Picture Courtesy of Rofin
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
RTP Conductive Resin:
Stainless Steel and Carbon Powder Filled PBT
(Shielding through Reflection and Absorption)
Results: • Uniform SE, even in sharp corners
• Better grounding
- All surfaces are now conductive
• Eliminates process steps
• Eliminates added supplier
• Improves yield
• Reduces total cost
Sensor Application Successes
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
• EMI 300 Series (PC)
• UL Listed V-0 @ 1/16”
• SE 40-60 dB
• Economical alternative to
metal or coated plastics
– Complex Design
Metal Replacement
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
RTP Product Base
Polymer Shielding Effectiveness
(3 mm @ 1.5 GHz)
EMI 261 PA 6/6 40 dB
EMI 262 PA 6/6 53 dB
EMI 263 PA 6/6 74 dB
EMI 1061 PBT 39 dB
EMI 1062 PBT 55 dB
EMI 2161 PEI 40 dB
EMI 2162 PEI 55 dB
EMI 2561 PC/ABS 38 dB
EMI 2562 PC/ABS 54 dB
Sample EMI Compounds from RTP
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Conclusions
• RTP’s EMI Shielding Compounds are:
– Capable of providing required levels of EMI shielding
– Allow for increased design freedom
– Provide precise combination of properties to meet
application requirements
– Cost effective alternative to other shielding methods
– Permanent and durable solutions
– We can test unique compounds for relative SE
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Advantages of RTP TCCs
• Customized performance to meet specific application
requirements (Conductivity, FR, Color, etc.)
• Independent polymer and filler selection
• Global manufacturing capability to minimize lead times
• Dedicated technical service to help optimize mold
design and processing for maximum TCC performance
in your specific application
YOUR GLOBAL COMPOUNDER OF CUSTOM ENGINEERED THERMOPLASTICS
Combining EMI + TC
• SSF is a poor thermal conductor
• Thermal fillers can provide some EMI shielding
• Custom formulations can balance design requirements
RTP
Formulation
Shielding
Effectiveness (300 MHz – 1.5 GHz)
Thermal
Conductivity (Through-plane)
Thermal
Conductivity (In-plane)
RTP EMI 2562 60 – 85 dB 0.3 W/mK N/A
299X124222C 30 – 55 dB 3.4 W/mK 25 W/mK
299X124222D 32 – 38 dB 3.1 W/mK 19 W/mK
299X124222E 40 – 60 dB 5.3 W/mK 32 W/mK
299X124223B 45 – 55 dB 1.4 W/mK 4.1 W/mK
Tworzywa nie z tej Ziemi … ABS (35 kolorów, transparent, galwanizacja, samogasnący), ASA, SAN, PC, PMMA, PA, PBT, POM, PPS, PS, EPS, PVDF PPH, PPC, PPR, PP metalocenowe, LDPE, HDPE, MDPE, PE metalocenowe, TPE: SBS, SEBS, TPV (EPDM/PP), wypełniacze kredowe, PP wypełniany…
Dziękujemy !
Thank you !
Informacje / Information
Korporacja KGL S.A.
http://www.kgl.pl
Email: [email protected]
M: +48 604 136 236
T: +48 22 321 30 00 ext. 221