New Energy Vehicle EMC Shielding: Application and Advantages of Copper Sheath+Magnesium Hydroxide Composite Structure
In recent years, a new type of EMC shielding solution - copper sheath+magnesium hydroxide composite structure, has gradually emerged in the industry. This technology combines the excellent conductivity of copper materials with the good dielectric properties and thermal stability of magnesium hydroxide, providing an efficient, environmentally friendly, and multi protective shielding solution for new energy vehicles.
1、 What is EMC? Why is it particularly important in new energy vehicles?
EMC， Electromagnetic compatibility refers to the ability of a device or system to operate normally in its electromagnetic environment without causing unacceptable electromagnetic interference to other devices. In new energy vehicles, electromagnetic interference is particularly prominent due to the extensive use of high-power electronic devices and high-frequency switching circuits.
For example:
The motor driver generates strong electromagnetic pulses during high-speed switching;
The connection line between high-voltage battery pack and charging system is prone to antenna effect;
Sensitive equipment such as vehicle communication modules and radar systems are susceptible to external electromagnetic interference.
If these problems are not controlled, they can lead to misoperation and signal distortion of on-board equipment, and in severe cases, affect the stability of the vehicle control system, and even endanger driving safety. Therefore, building an efficient and reliable EMC shielding system is an important task in the development process of new energy vehicles.
2、 Traditional EMC shielding methods and their limitations
At present, common EMC shielding methods mainly include metal shielding covers, conductive tapes, conductive coatings, and braided mesh cable sheaths. These methods each have their own advantages and disadvantages:
Metal shielding cover: Although it has good shielding effect, its large weight and high cost are not conducive to lightweight design;
Conductive tape/coating: easy to apply, but poor durability, prone to peeling or oxidation after long-term use;
Woven mesh sheath: suitable for cable shielding, but the shielding efficiency decreases significantly in the high-frequency range.
In addition, traditional shielding materials often use metal materials such as aluminum and copper. Although they have good electrical conductivity, they lack additional functions such as flame retardancy and thermal insulation, which limits their use in the complex working conditions of new energy vehicles.
3、 Technical principle of copper sheath+magnesium hydroxide composite structure
To solve the above problems, the industry has begun to explore composite shielding structures that combine multiple materials. Among them, the "copper sheath+magnesium hydroxide composite structure" is gradually becoming the preferred solution for high-end new energy vehicle models due to its excellent comprehensive performance.
1. The function of copper sheath
Copper is an ideal electromagnetic shielding material with the following advantages:
Excellent conductivity: can effectively reflect and absorb electromagnetic waves;
Strong ductility: easy to process into various shapes, suitable for complex structures;
Good thermal conductivity: Helps with heat dissipation and improves system stability.
Wrapping a layer of copper foil or braided copper wire around cables or components can significantly reduce electromagnetic leakage and improve overall shielding effectiveness.
2. The function of magnesium hydroxide
Magnesium hydroxide, as an inorganic flame retardant, has been widely used in the fields of electrical insulation and fire prevention in recent years. It not only has excellent thermal stability and flame retardancy, but also releases water vapor at high temperatures, playing a role in cooling and extinguishing fires.
Combining it as a filling layer or coating material with a copper sheath not only enhances the mechanical strength of the overall structure, but also provides additional fire protection in the event of short circuits or overheating.
3. Advantages of Composite Structures
The combination of copper sheath and magnesium hydroxide is not a simple physical superposition, but a synergistic structure formed through a specific process:
Dual functions of electromagnetic shielding and fire prevention: meeting EMC requirements while enhancing overall vehicle safety;
Lightweight design: Compared to traditional metal shielding structures, the overall weight is lighter;
Strong weather resistance: suitable for harsh environments such as high temperature, humidity, and vibration;
Environmentally friendly: Magnesium hydroxide is non-toxic and harmless, in line with the concept of green manufacturing.
4、 Practical application scenarios and case analysis
At present, some high-end new energy vehicle companies have begun to try to apply the "copper sheath+magnesium hydroxide composite structure" to the following key parts:
1. High voltage cable system
The high-voltage cables of new energy vehicles play an important role in power transmission and are one of the main sources of EMI. By using this composite structure for coating, not only can electromagnetic radiation be effectively suppressed, but the fire resistance level of the cable can also be improved to prevent fire accidents caused by short circuits.
2. Battery module casing
The internal structure of the power battery pack is complex, with concentrated heat and high susceptibility to electromagnetic interference. Adding a layer of copper sheath and magnesium hydroxide composite material inside the shell can not only isolate electromagnetic noise, but also serve as insulation and flame retardant, extending the battery life.
3. Motor controller
As the core component of the vehicle power system, the electromagnetic interference of the motor controller directly affects the performance of the vehicle. By integrating this composite shielding structure on the controller casing, interference to external devices can be significantly reduced and control accuracy can be improved.
Against the backdrop of the development of new energy vehicles towards high performance and intelligence, the importance of EMC shielding technology is becoming increasingly prominent. The copper sheath+magnesium hydroxide composite structure, as a new generation solution that combines electromagnetic shielding, flame retardancy, and lightweight advantages, is gradually changing the pattern of traditional shielding materials.
In the future, with the participation of more OEMs and suppliers, this technology is expected to be applied on a larger scale, providing strong support for the safety, stability, and sustainable development of the new energy vehicle industry.