Industry Background

With the rapid expansion of electric vehicle infrastructure in Germany and across European Union, manufacturers of EV charging stations face increasing electromagnetic compatibility (EMC) requirements.

Charging station control systems include:

• Power conversion modules

• Communication boards

• Smart metering units

• High-frequency switching components

These systems are highly sensitive to electromagnetic interference (EMI), especially in outdoor high-voltage environments.

Customer Profile

A mid-sized EV charger manufacturer supplying public charging stations in Europe contacted us with the following problem:

Their control PCB experienced signal instability during high-load operation, especially in fast-charging mode (DC 120kW).

Technical Challenge

During internal EMC testing, the manufacturer found:

• Radiated EMI exceeding regulatory limits

• Interference between power modules and signal boards

• Communication instability in CAN bus modules

• Occasional software reset events

The root cause analysis identified insufficient grounding and shielding around:

• IGBT modules

• DC-DC converter housing

• Control board enclosure gaps

Engineering Assessment

Our engineering team recommended using conductive copper foil tape with conductive acrylic adhesive to:

1. Seal enclosure gaps

2. Improve grounding continuity

3. Enhance shielding effectiveness

4. Reduce high-frequency noise leakage

Product Specification Supplied

• Material: 99.9% pure copper foil

• Thickness: 0.05mm copper + 0.03mm adhesive

• Adhesive type: Conductive acrylic

• Shielding effectiveness: 60–80 dB (30MHz–1GHz)

• Surface resistance: < 0.05Ω

• Temperature range: -20°C to 120°C

Custom options provided:

• Die-cut copper shielding strips

• Slit rolls for automated assembly

• Liner for precise placement

• 

Implementation Process

The tape was applied to:

• Internal enclosure seams

• PCB ground extensions

• Cable entry shielding points

• Converter housing overlap joints

Testing followed IEC EMC compliance procedures.

Measured Results

After implementation:

The charging station successfully passed European EMC certification testing.

Why Copper Foil Tape Works for EMI Shielding

Copper foil tape provides:

• High electrical conductivity

• Excellent grounding continuity

• Strong shielding effectiveness across wide frequencies

• Easy conformability for complex enclosures

Unlike aluminum tape, copper allows superior solderability and grounding reliability.

Common Applications of Copper Foil Tape

• EV charging stations

• Solar inverter shielding

• Telecom cabinets

• Medical imaging equipment

• Industrial control panels

FAQ Section

Is copper foil tape conductive on both sides?

It depends on adhesive type. Conductive adhesive versions provide through-adhesive conductivity, ensuring complete grounding continuity.

What thickness is best for EMI shielding?

For most industrial EMC applications, 0.05mm copper thickness provides strong shielding while maintaining flexibility.

Can copper foil tape replace metal gaskets?

In some light-duty EMI applications, copper tape is a cost-effective alternative to metal EMI gaskets.

Author & Technical Validation

This solution was developed in collaboration with our EMC engineering team with over 12 years of experience in industrial shielding materials and power electronics applications.

We provide:

• Shielding effectiveness test reports

• RoHS & REACH compliance documents

• Technical datasheets

• Custom die-cut solutions

CTA

Need a reliable copper foil tape manufacturer for EMI shielding applications?

Contact us for:

• Free samples

• Engineering consultation

• Custom die-cut design support

• Bulk pricing within 24 hours