Novel Composite for Automotive Electronic Components
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Powder Processing & Technology, LLC was presented with a patented novel EMI absorbing composite material that would be used to make distributed networks in both automotive and consumable electronics. The purpose of this material development was for suppression of electromagnet/radio (EMI/RFI) interference. With proper metallization, surface mount or feed-through filter elements could be fabricated with attenuation characteristics continuing out to gigahertz frequencies. Several patents had been filed for this composite material and its unique component design by our customer, the R&D Center for one of the big three US automotive manufacturing companies.
Although the customer developed the composite material, it was all in bench-top lab scale. The customer did not have the necessary scale up equipment or the industrial powder processing technology.
PPT had established a good reputation in manufacturing of quality NiZn ferrite powders when this customer approached us. This was after they had been disappointed with one of their component manufacturers who had a powder facility and then was awarded a license to produce composite components.
As we had experienced on many occasions, the very first 14 kg sample was qualified by the customer, so we jumped on 227 kg Pilot Plant scale production. The challenge was to be compatible to the counterpart material in composite. The counterpart material alone was already established in the market so change in that material did not seem to be an option. However, the customer decided to keep PPT's material and persuaded the counterpart to modify their material to be compatible to PPT's since ours showed superior characteristics that the customer would not want to trade.
The process involved raw materials formulating, calcining, milling, and spray drying and then blending homogeneously with the counterpart. PPT has been awarded a license to produce this novel composite material from this success.