As urbanization promotes the development of autonomous driving technology and the widespread application of advanced driver assistance systems (ADA), automotive original equipment manufacturers and suppliers are actively seeking high-performance materials to optimize today's higher frequencies (>75 GHz) , The performance of millimeter wave (mmWave) radar devices. To meet this demand, SABIC is launching two new materials-LNP Thermocomp WFC06I and WFC06IXP compounds-respectively for the front and rear housings of next-generation radar devices.
The new glass fiber reinforced polybutylene terephthalate (PBT) grade has extremely low dissipation factor (Df) and dielectric constant (Dk), which helps to support the transmission of high-frequency radar signals. They also feature ultra-low warpage, allowing designers to create new, thinner housings to improve signal transmission. In addition, these new Sabic products support high-speed, high-precision laser welding, which contributes to efficient radar unit assembly.
A related person stated: “As the automotive industry develops new vehicle technologies aimed at alleviating traffic congestion and improving safety in expanding urban areas, the development of advanced driver assistance systems (ADAS) is accelerating. Sabic is actively developing new materials to help ADAS designers achieve goals related to size and weight reduction, signal transmission accuracy and reliability improvements, and seamless integration with vehicles. We work closely with companies at all levels of the ADAS value chain to understand rapid changes and demanding requirements and provide Tailor-made high-performance material solutions to solve these problems."
Many ADAS designers are adopting higher-frequency millimeter-wave radar technology because of its improved image resolution and greater range to achieve safer driving under various conditions. However, compared to lower frequencies, frequencies in the 76 to 81 GHz band present greater transmission challenges. In order to improve wave transmission, the radome requires very low dissipation factor (Df) and dielectric constant (Dk), thinner walls, and a simplified design without supporting structures. Existing glass-filled PBT materials generally do not meet these transmission optimization requirements; for example, their Df performance is greater than 0.01. In addition, as semi-crystalline polymers, they have a high tendency to warp when used in thin-walled parts without supporting structures, which may cause parts to fail during assembly, transportation, and use.
SABIC's LNP Thermocomp material exceeds the existing PBT material in terms of Df/Dk performance and warpage control, and can reduce the attenuation of electromagnetic waves passing through the radome to help improve image resolution and distance. They also enhance the transmission capacity and minimize the deviation of the signal beam, thereby improving the image quality. In addition, the new LNP Thermocomp compound provides higher ductility to improve impact resistance and has the same moisture and chemical resistance compared to existing PBT materials.
Laser welding is a fast and efficient process that can speed up production. Laser welding of plastic parts has many advantages, including the ability to produce miniaturized and highly complex parts without the use of consumables such as adhesives and fasteners. Precise and firm welding can protect sensitive electronic equipment from dust and moisture.
SABIC's LNP Thermocomp WFC06I material is used for the radar front cover, and its laser transmission rate exceeds 60%, which is 20% higher than the nearest competitor. Customers can use its wide laser window and low laser power to potentially increase productivity. Another new grade-LNP Thermocomp WFC06IXP material-is used as an absorber layer for laser welding.
Relevant personnel said: "To give full play to the potential of automotive radar in assisted and autonomous driving, improvements in design, performance and production efficiency are required. SABIC continues to open up new horizons in the field of materials science, with the goal of solving customers’ problems in optimizing ADAS design. Challenge. Our new glass fiber-reinforced PBT material helps support the adoption of new technologies such as millimeter wave radar with enhanced functions."