Boost 800V EV Applications with Kapton® and Nomex® Tapes
As the automotive industry continues to shift towards electric vehicles (EV), high-performance electric motors are getting more and more attention. New developments aim to combine higher power and performance with less space, weight and rare materials. These developments require special materials and solutions to protect components from increasing stresses in the electric motor and enhance its durability and lifetime.
Special adhesive tapes made with Kapton and Nomex materials have proven to be essential for 800V electric vehicle applications.
In this blog post, Mattia Villella, Products and Portfolio Manager, EMEA at Saint-Gobain® Tape Solutions, will help us understand the benefits of tapes created with Kapton and Nomex materials and how they can help improve the performance and durability of electric motors in EVs.
EV drivers expect better performance, long range and fast charging. This pushes OEMs and component manufacturers to reach new performance levels.
One way to reach better performance levels is by increasing the battery voltage from commonly used 400-volt systems to 800-volt architectures. Let’s have a deeper look at the why.
Mattia, why is 800V currently trending in EV motor applications?
Higher battery voltage can increase efficiency, performance and create weight savings for EV components such as motors and inverters. In addition, high battery voltage allows faster charging and less energy consumption for vehicles.
For instance, by doubling the voltage from 400 to 800 at an equal current, the amount of energy per unit of time to charge a battery can be significantly increased.
Higher voltage also helps reduce heating issues and power losses while extending the lifetime of the battery pack at the same time, making the entire system more efficient.
But high battery voltages from 600 to 900 volt that are commonly summarized as 800V architecture, come with new challenges for other components as the architecture of an EV is a complex system.
To deal with new demands of high voltage battery design, other components in the EV need to be adapted and protected though strong insulation. This is where adhesive tapes made with special backings like Kapton and Nomex come into play.
Mattia, what are Kapton and Nomex tapes and why are they beneficial for high voltage EV design?
Kapton tapes are made of a polyimide film that provides high-temperature stability and high dielectric strength, making it an excellent insulator for various components and EV applications. It is also resistant to chemicals and radiation and has strong mechanical resistance. Kapton can also be laminated to other technical substrates and coated with different adhesives to ensure ideal performance and facilitated use in different scenarios.
Tapes made with Nomex materials also provide high-temperature resistance due to the aramid fibers used. These also provide good resistance to abrasion, tearing, and punctures, making them a good choice for high-stress environments. Performing as an excellent insulator with high temperature resistance, Nomex tapes are used in a wide spectrum of applications in the electro-mechanical industry and electric motor applications.
How are Kapton and Nomex tapes used in electric vehicles, specifically 800V applications?
Kapton and Nomex tapes are used in a variety of applications in electric vehicles, including battery packs, electric motors, and power electronics. They are used to insulate wires and components, protect them from high temperatures and abrasion and prevent electrical discharge.
In EVs with 800V design where maximum electric power is used, excellent electrical insulation, high temperature resistance and the ability to withstand mechanical stresses is required. Kapton and Nomex tapes are used to insulate high-voltage components like battery packs and inverters and reduce the risk of electrical arcing and short circuits.
These strong properties are also essential for 800V design applications outside the vehicle itself: in fast and ultra-fast EV charging stations. To maximize charging speed of high-voltage battery packs, high voltage is needed. Therefore, Kapton and Nomex materials help to protect and insulate components in charging equipment and prevent arching and shorts.
With the trend to increase power of electric vehicles and even more in heavy-duty EV applications like in busses, trucks, agriculture and specialty vehicles where power even beyond 800V are in design, the need for special tapes and materials to protect components from enormous stresses is growing. But as finding the right tape solutions for specific applications and requirements can be tricky, your tape expert can guide you through the process in solving toughest challenges and keeping your EV projects rolling.
Kapton and Nomex are registered and owned by Dupont.