The electrification of vehicles is transforming the automotive industry and bringing significant advancements and challenges. Among the most pressing challenges is the management of electromagnetic noise, particularly in the low-frequency band.
As electric vehicles (EVs) replace internal combustion engines with electric motors and inverters, the nature of noise generated within the vehicle’s systems has shifted, necessitating innovative solutions. Enter permalloy film, a material poised to revolutionize noise suppression in EVs, offering ultra-thin, lightweight, and highly effective shielding against unwanted interference.
The noise-suppression challenge
As vehicles become increasingly electrified, the demand for effective noise suppression has grown. Traditional gas-powered automobiles relied on internal combustion engines, with most of the noise being high-frequency, typically measured in megahertz (MHz). These vehicles’ information, communication, and navigation subsystems added to the overall noise but generally stayed within the high-frequency spectrum.
On the other hand, EVs eliminate internal combustion engines and introduce electric motors and inverters. These components generate low-frequency noise, often measured in kilohertz (kHz), which presents a unique challenge.
Low-frequency noise is more pervasive and can interfere with the performance of sensitive electronic components within the vehicle. Conventional noise suppression methods, such as thick metal shields, are often bulky and heavy, making them unsuitable for modern EVs, where minimizing size and weight is critical.
This shift in noise characteristics has necessitated the development of new materials and technologies to effectively suppress low-frequency noise. One such innovation is using permalloy film, a material with exceptional magnetic properties that can significantly enhance noise suppression while adhering to the stringent design requirements of EVs.
The permalloy film solution
Permalloy film is an alloy with extremely high magnetic permeability, which allows it to effectively absorb and shield against electromagnetic interference (EMI), particularly in the low-frequency band.
Figure 1. The part number construction shown here highlights the layered design achieved with ultra-thin, lightweight, and highly effective permalloy film material.
Effective noise reduction is essential in industrial environments to ensure the smooth operation of machinery and sensitive electronics. With the growing complexity of systems and increased electronic equipment prone to electromagnetic interference, many industries are seeking efficient noise suppression solutions that don’t add unnecessary weight or bulk.
Traditional shielding materials are often heavy and thick, posing limitations in applications where minimizing size and weight is crucial — such as in compact manufacturing systems, robotics, and automated equipment. However, permalloy thin film sheets, carefully designed to address the noise suppression needs of today’s EVs, are providing a promising solution.
Ultra-thin permalloy film sheets can offer a tailored solution to these industrial noise challenges. These sheets are designed with high permeability and reduce low-frequency noise and electromagnetic interference that can disrupt sensitive equipment (Figure 2). These permalloy films maintain high performance while fitting seamlessly into existing setups without adding unnecessary size or weight.
Figure 2. Permalloy alloy with extremely high permeability can be formed into thin film sheets, suppressing low frequency band noise more effectively than conventional shielding materials and metal shields while reducing weight in automobiles.
This technology provides a practical, scalable solution to electromagnetic noise control for industries focused on achieving higher operational efficiency and reliability, supporting optimized equipment performance in diverse industrial settings. It’s addressing the noise suppression challenges posed by vehicle electrification while aligning with the broader trend in the automotive industry toward lighter, more efficient components.
EV applications
The application of permalloy film in EVs is versatile and far-reaching. One of the key advantages of this material is its ability to be used in various configurations, depending on the vehicle’s specific noise suppression needs. Permalloy film can encase entire installations, individual components, or even particular wires, providing targeted noise suppression where required. This flexibility allows engineers to design custom solutions that maximize performance while minimizing added weight and space.
Moreover, permalloy film can be seamlessly integrated into existing vehicle designs. It can be retrofitted to enhance the performance of existing systems without requiring significant changes to the vehicle’s architecture. This capability is precious in the automotive industry, where design constraints often limit introducing new materials or technologies.
By adding permalloy film to existing designs, manufacturers can improve noise suppression without compromising the vehicle’s overall performance or efficiency.
These permalloy sheets are available in standard sizes, such as 300 mm (L) x 200 mm (W), and can also be customized to meet specific design requirements (Figure 3). This adaptability allows the film to be precisely tailored to the unique demands of each application, delivering optimal noise suppression without adding unnecessary bulk.
Infrastructure benefits
Though initially designed for the automotive industry, the potential applications for permalloy film extend beyond EVs. One promising application is in EV charging stations for home and commercial settings.
Figure 3. With this measurement set up, electronic equipment has the ability to become smaller, thinner, and more multifunctional, meeting the need for noise suppression in smartphones and other devices. By using permalloy sheeting, it’s possible to suppress noise at 1/5th the thickness of conventional products.
As EV adoption grows, the demand for reliable, interference-free charging infrastructure also rises. These charging stations, particularly in urban environments with high installation density, can contribute to electromagnetic interference that affects nearby electronic devices and systems. By integrating permalloy film into these stations, manufacturers can help mitigate interference, ensuring smooth, reliable operation while supporting the broader expansion of EV infrastructure.
Permalloy film can be used in these charging stations to suppress low-frequency noise, ensuring the charging process is efficient and does not interfere with other electronic equipment. This application is particularly relevant in commercial charging stations, where multiple vehicles may charge simultaneously, leading to higher levels of EMI. By integrating permalloy film into the design of charging stations, manufacturers can reduce interference and improve the overall reliability of the charging infrastructure.
The properties that make permalloy film effective in EVs — its high permeability, lightweight design, and superior shielding capabilities — are equally valuable in consumer electronics. By incorporating permalloy film into the design of these devices, manufacturers can also reduce electromagnetic interference and enhance overall performance without increasing the size or weight of the product.
Conclusion
The introduction of permalloy film marks a significant step forward in the ongoing effort to manage electromagnetic noise in electric vehicles. As the automotive industry continues to evolve toward electrification, the need for lightweight, effective noise suppression solutions will only increase. Permalloy film offers a promising solution, combining high performance with minimal impact on vehicle design.
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