Automotive EMI Shielding for EV Chassis Controllers Supporting ASIL-D
EMI Shielding Is Critical to EV Chassis Domain Safety
As intelligent electrification accelerates, new energy vehicles (NEVs) are rapidly evolving from mechanical architectures toward highly integrated, software-defined platforms. The Chassis Domain Control System (CDCS)—responsible for braking, steering, suspension, and vehicle stability—is widely regarded as the vehicle’s safety nerve center.
Operating under high voltage, high current, strong vibration, and complex electromagnetic environments, chassis domain controllers are extremely vulnerable to electromagnetic interference (EMI). Any EMC-related malfunction may directly compromise vehicle safety and jeopardize ISO 26262 ASIL-D functional safety compliance.
As a leading provider of automotive EMI shielding and thermal management solutions, Konlida delivers multi-layer, automotive-grade EMC protection designed specifically for EV chassis domain controllers—ensuring long-term reliability, safety, and regulatory compliance.
EMC Challenges in Chassis Domain Control Systems
Modern chassis domain controllers integrate multiple safety-critical subsystems, including IPB/IBC braking, steer-by-wire (SBW), active suspension, and ESP. These systems face several EMC risks:
Key EMI Risk Factors
| EMC Challenge | Technical Description |
|---|---|
| Dense interference sources | Proximity to e-motors, HV battery packs, DC-DC converters with switching noise up to MHz levels |
| High signal sensitivity | Low-level sensor signals (wheel speed, steering angle, acceleration) are easily disturbed |
| Extreme safety requirements | Any EMI-induced malfunction may violate ASIL-D safety targets |
| Harsh operating conditions | Long-term exposure to -40°C to 125°C, humidity, salt spray, oil contamination, and vibration |
Conventional shielding methods often fail to balance performance, durability, and cost, highlighting the need for automotive-grade EMI shielding materials and system-level EMC design.
Konlida’s Full-Stack Automotive EMI Shielding Strategy
Konlida adopts a system-level, board-level, and cable-level EMC protection architecture, supported by proprietary materials and precision manufacturing.
System-Level Shielding: Building a Reliable Faraday Cage
Application areas
Controller enclosures, housing seams, I/O interfaces, inspection windows
Key solutions
| Product | Performance Highlights |
|---|---|
| High-conductivity shielding foam | Surface resistance ≤0.2 Ω, shielding effectiveness ≥80 dB (30 MHz–1.5 GHz), compression set <10% |
| High-temperature conductive rubber | Nickel-carbon or silver-plated copper fillers, operating temperature up to 160°C, IP67 compatible |
Engineering value
Effectively suppresses both radiated emissions and external interference, enabling compliance with CISPR 25 Class 5 and ISO 11452-2—a foundation of automotive EMC compliance.
Related insight:
What Is Electromagnetic Shielding? The Science Behind EMI Protection
Board-Level Shielding: Protecting Critical Chips
Application areas
MCUs, power modules, high-speed communication ICs on PCBs
Key solutions
| Material | Key Advantages |
|---|---|
| SMT Gasket | Reflow soldering compatible up to 260°C, stable grounding, vibration-resistant alternative to spring contacts |
| Flexible conductive PI film | Thickness ~0.05 mm, shielding effectiveness 70–100 dB, temperature range -40°C to 200°C |
Engineering value
Enhances localized EMI immunity and preserves high-speed signal integrity—meeting the robustness requirements of ASIL-D safety-related signal paths.
Related reading:
SMT Gaskets: High-Precision EMI Shielding and Automation-Ready Solution
Cable-Level Shielding: Securing Signal Pathways
Application areas
Mixed high-voltage and signal harnesses connecting brakes, steering actuators, and suspension modules
Key solution
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Omnidirectional conductive foam tape providing 360° shielding, strong adhesion, solvent resistance, and long-term aging stability
Engineering value
Prevents cable-to-cable crosstalk and external field coupling, ensuring accurate and reliable signal transmission throughout the chassis network.
Electro-Thermal Co-Design: Enhancing System Robustness
Beyond EMI control, Konlida integrates thermal management to improve long-term EMC stability:
| Thermal Solution | Benefit |
|---|---|
| Copper-graphite composite sheets | Thermal conductivity ≥450 W/m·K |
| Thermal interface silicone pads | Maintain stable operating temperatures |
Effective heat dissipation reduces component stress, indirectly improving EMI resistance and extending system lifespan—supporting functional safety objectives.
Why Konlida for Automotive EMI Shielding
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Automotive-grade compliance: Materials meet AEC-Q200, ISO 16750, USCAR standards
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ASIL-D readiness: Proven support for ISO 26262 functional safety systems
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End-to-end customization: From EMC simulation and material selection to die-cutting and SMT assembly
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Environmentally compliant: RoHS and halogen-free certified materials
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Proven mass production: Successfully deployed in chassis control platforms of leading NEV OEMs
Industry perspective:
Why Leading Brands Choose Konlida as Their Conductive Foam Supplier
Enabling Safer Intelligent Mobility
In next-generation electric vehicles, EMC is no longer optional—it is mandatory. As a cornerstone of intelligent automotive safety, automotive-grade EMI shielding directly determines whether chassis domain controllers can meet the highest ASIL-D functional safety standards.
With advanced materials, system-level EMC thinking, and scalable manufacturing, Konlida delivers reliable, validated, and production-ready EMI shielding solutions for EV chassis domain control systems. Looking ahead, Konlida will continue advancing automotive EMC technologies, partnering across the value chain to secure the safety foundation of intelligent mobility and sustainable transportation.
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