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Injection molded absorbing material with integrated structure and function
In the electromagnetic compatibility (EMC) design of electronic devices, engineers usually handle it by first designing structural components (shells, brackets, shielding covers), and then attaching absorbing wave plates, applying absorbing coatings, or installing shielding pads where needed. This design process of separating "structural function" means additional parts, additional assembly processes, and additional costs.
But what if the structural components themselves can absorb waves?
�� Core idea:Injection molded absorbing materials were born based on this idea. It blends electromagnetic wave absorbers with polymer matrices at the material level, enabling injection molded parts to have dual functions of structural load-bearing and electromagnetic wave absorption. A car radar bracket, a communication equipment housing, and a waveguide terminal load - injection molded directly with absorption capability. This is not only an innovation at the material level, but also a shift in the EMC engineering design paradigm: from "post remediation" to "functional embedding".
Injection molded absorbing materials are electromagnetic functional composite materials formed by injection molding a plastic matrix containing conductive or magnetic fillers. They can be used to absorb and attenuate electromagnetic wave signals to reduce electromagnetic interference (EMI) or improve the electromagnetic compatibility (EMC) of the system.
Thermoplastic polymers, such as PA, PC, PBT, PPS, PP, etc., determine mechanical properties, temperature resistance, and processability.
Magnetic materials (ferrite, Permalloy, etc.) or conductive materials (carbon powder, graphene, etc.), with a volume fraction of 20-60%.
| Dimension | Injection molded absorbing material | Traditional absorbing sheet/foam/coating |
|---|---|---|
| form | Three dimensional structural components (shells, brackets, etc.) | Two dimensional sheet, roll or coating |
| Function Positioning | Structural functional integration | Pure functional layer, to be attached to structural components |
| quantity of parts | An injection molded part replaces the 'structural component absorbing wave plate' | At least two independent components |
| Assembly process | Installation completed in one go | Installation of structural components and attachment of absorbing materials |
| Adaptability to complex shapes | Excellent (injection molding) | Restricted (sheet material difficult to adhere to curved surfaces) |
| Large scale cost | Low (injection molding mass production) | High (cutting, pasting) |
| performance consistency | High (stable injection parameters) | Greatly affected by the attachment process |
Core values:Injection molded absorbing materials embed the absorbing function into the structural components themselves, bypassing the dilemma of "extra space" in traditional solutions - the structural components themselves are absorbing bodies.
Melt flow causes orientation of sheet-like fillers, affecting the anisotropy of magnetic permeability and dielectric constant.
The minimum wall thickness is about 1.25mm, and ultra-thin applications are limited, but it is suitable for most structural components.
Annealing can increase tensile strength by 22%, impact strength by 28%, and W-band shielding effectiveness by 99%.
| Substrate system | Typical product | Density (g/cm ³) | Working temperature (° C) | Key Features | Typical Applications |
|---|---|---|---|---|---|
| PA | MF-PA-120 | 4.27 | Up to 170 | High mechanical strength, high temperature resistance | Waveguide terminal, structural absorber |
| PPS | MF-PPS | 4.48–4.66 | Reflow resistant soldering | UL94 V0、 Low gas release | Phased array antenna, satellite communication |
| PP | JCP-PP9 | 0.9 | -40 to 100 | Lightweight, high impact strength | Automotive radar bracket |
| PBT | MW1000 series | — | -50 to 160 | Millimeter wave frequency band, adjustable dielectric constant | 5G communication, microwave cavity |
JCP-PP9 reaches 160dB/cm at 77GHz; GXS exceeds 80dB/cm at 24GHz.
Conventional 1-18GHz; Millimeter wave frequencies of 35-100GHz and 60 GHz.
MF-PA-120 tensile strength 47MPa; MF-PPS tensile strength~55MPa; JCP-PP9 has a bending strength of 20MPa.
Range 113 ° C – 245 ° C; MF-PA-120 operates at 170 ° C; GXS-PAK undergoes thermal deformation at 200 ° C.
Adjustable from 1.02-3.64g/cm ³, with PP base as low as 0.9g/cc.
MF-PPS and MW1000 series have passed UL94 V0.
The 77GHz radar bracket absorbs reflections and reduces sidelobe interference; JCP-PP9 and GXS thermoplastic particles are widely used in automotive radar absorbing covers and brackets.
Optical modules, routers, antennas, etc. can be injection molded instead of adhesive to reduce reflection and suppress cavity resonance.
MF-PPS/PA is used for phase shifters, board level absorbers, and waveguide attenuators, with both low gas release and high temperature resistance.
The MW1000 series includes waveguide terminals, attenuators, and microwave cavities to increase antenna gain and reduce resonance.
Select universal type for 1-18GHz; Choose JCP PA series for 35-100GHz; Select PP based for 60 GHz.
Choose PP at 80-100 ° C; PA at 120-150 ° C; PA/PPS at>170 ° C; Reflow soldering requires PPS.
Choose PA for high load-bearing capacity and PP for lightweight.
Automotive/communication/aerospace require UL94 V0 and RoHS/REACH compliance.
The advantages of complex shapes and large-scale injection molding are obvious; Low yield or prototype can be considered for machining evaluation.
The essence of injection molded absorbing materials is to "embed" the electromagnetic wave absorption function into the engineering solution of the structural component itself. It is not about using absorbing materials to "replace" structural components, but about allowing structural components to "learn" to absorb waves - by blending magnetic or conductive fillers with thermoplastic matrices, an injection molded part can simultaneously carry the tasks of "supporting and fixing" and "electromagnetic absorption".
From 77GHz automotive radar brackets to phased array antenna phase shifters, from 5G communication housings to satellite waveguide terminals - injection molded absorbing materials are pushing EMC design from "post attachment" to "functional embedding". Understanding the temperature resistance boundaries of different substrate systems, frequency responses of different filler systems, and the impact of injection molding processes on performance - these are the key to upgrading injection molded absorbing materials from a "new material" to an "engineering decision".
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