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Engineering Materials

How to ensure high-voltage systems for electric vehicles meet the most stringent safety standards

In the push towards connected cars and autonomous driving, more and more of the vehicle’s systems are becoming electric. In 1970, electronics accounted for 4% of the value of a car. Today, electronics represent 35% of the vehicle’s value. This number is expected to climb to 50% by 2030, according to Statista: Automotive electronics cost as a share of total car cost worldwide

The push to autonomous driving, combined with tighter emission regulations, dropping battery prices, better charging infrastructure and longer driving ranges, is causing analysts to predict that electric vehicles will represent a total share of 35% of new vehicles sold in 2025. Peak demand will occur in mega-cities with the most stringent emissions regulations.

Decreasing charging time will lead to increase in consumer demand

To make electric vehicles appealing to consumers, battery-charging times need to come down. This can be done with high-voltage charging and interconnection systems, which will also ensure the battery can produce sufficient power to drive the main e-motor. Yet high-voltage systems introduce new challenges for the materials used in the connectors.

Engineers need to meet strict design parameters for dielectric strength, creeping, tracking resistance and the ability to color code various electrical systems. The orange color selected for the high-voltage systems and main battery charging path helps operators and rescue teams enable safe handling, either during maintenance or in the event of an accident.

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At DSM, our portfolio includes a wide range of flame retardant materials engineered to deliver the required electrical performance for the high-voltage systems in electric vehicles. Based on Akulon polyamide (PA6), PA66, or PPA within the ForTii family, these materials deliver the high mechanical strength polyamides are known for, as well as Comparative Tracking Index (CTI) of more than 600V, dielectric strength above 30kV, and a Relative Temperature Index (RTI) of 140°C. The materials also work in a variety of assembly designs, including press fit, wave soldering, and reflow soldering.

ForTii Ace JTX8 is the only material available that meets JEDEC MSL1, with no blistering over an infinite shelf life. Its high mechanical strength provides excellent reliability both during and after assembly, retaining its mechanical performance after years of use in harsh conditions.

ForTii T11 is a UL94-V0–rated material at 0.2mm, delivering the highest level of flame retardancy available. Combining the dimensional stability and low moisture absorption of polyesters together with the high mechanical strength of polyamides, the materials in our portfolio are free from halogen, red phosphorous, and ionic heat stabilizers – ensuring high-performance materials that are environmentally friendly.

Learn more about how to meet the most stringent safety standards in high-voltage systems for electric vehicles. Download the full white paper here.

You can contact us and visit plasticsfinder.com for additional information about ForTii Ace JTX8 and  ForTii T11, including technical data sheets.

Dr Tamim Peter Sidiki

Global Marketing Director Electronics at DSM Engineering  Materials

Published on

25 March 2019

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ABOUT THE AUTHOR

Dr Tamim Peter Sidiki

Global Marketing Director Electronics at DSM Engineering  Materials

Dr. Tamim P. Sidiki is Global Marketing Director Automotive and Consumer Electronics. Tamim holds a Master Degree in Physics and a Ph.D. in Electrical Engineering obtained at Universities in Germany, Sweden and Scotland. Tamim has more than 20 years experience in the Consumer and Automotive Electronics Industry and is with DSM since October 2007.

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