EMI Shielding Applications: Essential Scenarios in Modern Electronics

Electromagnetic interference (EMI) shielding is a crucial engineering technology across multiple industries. It ensures that devices neither emit excessive electromagnetic noise nor suffer from external signal interference, maintaining stable performance and regulatory compliance.

Communication Infrastructure

In 5G base stations and communication equipment, high-frequency signals are highly susceptible to interference. EMI shielding materials prevent signal leakage between modules, ensuring signal integrity and system reliability. Conductive gaskets and foams are commonly applied at chassis seams to maintain electrical continuity and block electromagnetic leakage.

Plasma surface activation technology can significantly increase the surface energy of substrates (>50 mN/m), improving the adhesion between coatings and polyurethane bases — a critical pre-treatment process for long-term conductive stability.

Industry requirements:

• Excellent thermal stability and aging resistance for outdoor or high-temperature operation.

• High shielding effectiveness across wide frequency ranges (3.5 GHz, 28 GHz, 39 GHz) exceeding 70 dB.

• Surface resistance ≤ 0.05 Ω/sq to ensure conductivity stability.

• Precision and ultra-thin designs (below 0.5 mm) to fit compact base station structures.

Automotive Electronics

Modern vehicles integrate complex electronic systems including ADAS, infotainment, and powertrain control. Millimeter-wave radars operating at 77 GHz demand precise EMI control to prevent false detection and ensure safety.

Reliable shielding materials must endure vibration, temperature cycling, and environmental stress. Conductive foam gaskets with stable compression and rebound properties help maintain consistent contact pressure and shielding effectiveness over time.

Using coupling agents between the substrate and metal coating forms chemical bonding, enhancing interfacial stability and preventing delamination under thermal cycling. A gradient transition layer design also mitigates thermal expansion stress, ensuring long-term coating integrity.

Industry requirements:

• Must pass temperature cycling tests (-40 °C to 125 °C, over 1000 cycles), vibration tests (5–500 Hz, 10 G), and chemical resistance tests (oil, detergents, etc.).

• Compliance with automotive-grade standards such as AEC-Q200 for 15-year durability.

• Preference for low dielectric constant and low loss factor materials to support ADAS signal integrity.

Industrial Automation

In industrial environments, inverters, PLCs, and motor controllers generate strong electromagnetic noise. Without proper shielding, nearby sensitive circuits may malfunction, causing system interruptions.

EMI shielding materials in industrial automation must also resist moisture, dust, and chemical exposure. Salt spray resistance (ASTM B117) is a key measure of long-term material reliability under harsh conditions.

Introducing an alloy transition layer between nickel and copper coatings can relieve stress caused by thermal expansion mismatch, enhancing mechanical stability under temperature variations.

Industry requirements:

• High protection levels (IP54 and above) and strong corrosion resistance.

• UL94 V-0 flame retardancy for fire safety.

• Low compression set (≤ 10%, ASTM D3574) for sustained contact pressure over years of use.

• Reusability — the material should maintain performance after multiple installations and removals.

Consumer Electronics

In smartphones, tablets, and wearables, high-speed digital circuits are densely integrated within compact spaces. EMI shielding prevents signal crosstalk between processors, memory, and wireless modules (Wi-Fi, Bluetooth, etc.).

Ultra-thin, lightweight shielding solutions such as thin conductive foam are favored for saving space without compromising performance.

Pulse electroplating technology improves coating crystallinity and ductility, preventing cracks during compression or bending and ensuring continuous conductivity.

Industry requirements:

• Ultra-thin (0.3–0.8 mm) and flexible structures suitable for compact, curved designs.

• Rapid die-cutting capability and adhesive backing for efficient assembly.

• RoHS and REACH compliance — halogen-free and heavy metal-free materials.

• Cost-effective production aligned with fast product turnover cycles.

Konlida's Practice in EMI Shielding Solutions

Konlida provides customized conductive foam and EMI shielding materials tailored to diverse industry needs. Each product undergoes rigorous testing based on international standards:

• Surface resistance: ASTM D4935

• Contact resistance: MIL-STD-202G

• Environmental durability: ASTM B117 (salt spray)

• Mechanical compression: ASTM D3574

By focusing on measurable, repeatable parameters, Konlida supports customers in achieving reliable EMI shielding performance across applications from 5G infrastructure to automotive radar systems.

Industry-specific solutions include:

• Telecommunication: high-conductivity, ultra-thin, heat-resistant conductive foam

• Automotive: high-resilience, wide-temperature, salt-resistant materials

• Industrial: flame-retardant, corrosion-resistant, low-deformation foams

• Consumer electronics: lightweight, eco-friendly, easy-to-process shielding solutions

Through continuous innovation in material science and standardized testing, Konlida delivers high-performance EMI protection for advanced electronic systems worldwide.