Over the years, electronic subsystems have been added to gas-powered automobiles for information, communications, and navigation. All of those subsystems generate high-frequency noise measured in megahertz (MHz). Electric vehicles (EVs) also integrate all of those electronic subsystems, but they eliminate internal combustion engines and replace them with electric motors and inverters that generate lower-frequency noise in the kilohertz (kHz) range. Conventional noise suppression in the kHz band requires thick shielding materials, some of which are metal. The problem is that these materials are too bulky and too heavy for EVs, where minimizing size and weight are top priorities.
According the the Japanese material sciences company, the new IPM01 series of ultra-thin noise suppression sheets is made with an extremely high permeability alloy, formed into thin film sheets, meaning it can suppress low frequency band noise more effectively than conventional shielding materials and metal shields while reducing weight in automobiles. Compared to conventional TDK products, the thickness is reduced by about 80%, the weight by 90%, and the shielding effect is +65% [@1MHz], while being able to sustain operating temperatures from -40 °C to +85 °C, as required for automotive subsystems.
Moreover, this new permalloy might have applications beyond the automotive market. As electronic equipment becomes smaller, thinner, and more multifunctional, noise suppression for smartphones and other wearable devices is becoming increasingly important. By using the permalloy sheet developed by TDK, it is possible to suppress noise at 1/5 the thickness of conventional products.
TDK also explains that these sheets have good shielding characteristics over a wide bandpass from low to high band frequencies, and since the permalloy alloy surface is a conductor, the noise suppression effect can be further enhanced through grounding.
The IPM01 series in the Flexield family is available as sheet material (300 mm (L) x 200 mm (W)), in conductive or non-conductive double-sided tape, and in custom shapes. TDK also provides these materials in production-oriented rolls and high-temperature types.
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