DuPont Materials for HEV and EV Electrical Insulation

As new high-performance motor technologies become available for hybrid electric vehicles (HEVs) and fully electric vehicles (EVs), manufacturers are looking for insulating materials to manage these high-temperature environments.

DuPont™ provides improved electrical insulation materials for both battery and high performance motor applications. Materials include Nomex®, Kapton®, and DuPont Teijin Films Mylar®.

Nomex® paper and laminate insulation materials provide a number of benefits for HEV and EV applications, including:

• Reliable insulation systems for high temperature and power
• Long term electrical dependability 
• Thermal rating to UL 220ºC 
• UL insulation rating 
• High tear strength and tensile strength

Kapton® is a polyimide film designed for motor and wire insulation to ensure careful isolation of wires and components and enhance protection from harsh operating conditions.

Kapton provides the following advantages:

• Excellent electrical properties and increased voltage endurance
• High temperature durability for smaller size motors producing the same power 
• Long-term electrical reliability 
• Heat protection and dissipation capabilities 
• Low moisture uptake and high moisture release characteristics

DuPont Teijin Films™ Mylar® is a polyester film well-suited for motor and magnet wire insulation, optical film for displays, and electronics and micro-electronics applications. Made from PET (Polyethylene terephthalate) polyester, Mylar delivers:

• Excellent electrical insulation properties
• Predictable dimensional changes and flatness 
• Very thin film 
• Excellent resistance to heat, abrasion, chemicals, and moisture 
• Smooth, clean surface 
• Ease-of-handling 
• Cut-through and tear resistance

Fabrico works with DuPont insulation materials to provide HEV/EV manufacturers with the innovative solutions necessary to produce the next generation of vehicles.

Fabrico offers a wide range of custom fabrication services, including product engineering, material sourcing, prototyping, converting, laminating, complex printing, custom die-cutting, rotary die-cutting, and water jet and laser cutting

In addition, Fabrico is working on insulation and heat management/dissipation materials for battery manufacturers developing HEV and EV products. In these applications, Fabrico can provide materials expertise to address the following requirements:

• Dissipating/removing heat 
• Providing electrical insulation 
• Maintaining electrical contact 
• Shielding sensitive components from environmental conditions and debris 
• Cushioning and absorbing vibration