New Energy Vehicles insulation materials
Insulation Materials for New Energy Vehicles (NEVs)
New Energy Vehicles (NEVs), including Battery Electric Vehicles (BEVs), Plug-in Hybrid Electric Vehicles (PHEVs), and Fuel Cell Vehicles (FCVs), operate under high-voltage systems ranging from 400V to 1000V+. Insulation materials are critical for ensuring electrical safety, thermal management, flame resistance, and long-term reliability.
1. Laminated &Molded Insulation Materials
| Material |
Grade |
Key Properties |
Typical Applications |
| Epoxy Glass Fiber Laminate |
G10 |
High mechanical strength, excellent insulation |
Battery pack supports, insulating spacers |
| Flame-Retardant Epoxy Glass Laminate |
FR-4 |
Flame retardant, high dielectric strength |
Power electronics insulation, structural components |
| High-Temperature Epoxy Glass Laminate |
G11 |
Excellent heat resistance (180°C) |
Motor insulation systems |
| Glass Mat Reinforced Polyester |
GPO-3 |
Arc resistance, tracking resistance |
Busbar supports, battery disconnect systems |
| SMC Sheet Molding Compound |
SMC |
High strength, lightweight, flame resistant |
Battery covers, HV electrical housings |
2. Flexible Insulation Materials
| Material |
Thermal Class |
Key Features |
Applications |
| DMD Insulation Paper |
Class B (130°C) |
Good electrical insulation |
Auxiliary electrical insulation |
| NMN Insulation Paper |
Class H (180°C) |
High thermal endurance |
EV drive motors |
| NHN Insulation Paper |
Class H (180°C) |
Superior dielectric strength |
High-performance motors |
| Polyester Film (PET) |
Class B (130°C) |
Flexible, cost-effective |
Wire wrapping and cable insulation |
| Polyimide Film (PI) |
Class H/C (220–240°C) |
Excellent heat resistance |
E-motor slot insulation |
| Aramid Paper (Nomex®) |
Class H (180°C+) |
Flame retardant, durable |
Traction motors, battery insulation |
3. Motor Insulation Materials
| Material |
Thermal Class |
Applications |
| NMN |
Class H (180°C) |
Motor winding insulation |
| NHN |
Class H (180°C) |
High-performance traction motors |
| Polyimide Film |
Class C (220°C) |
Slot liners and phase insulation |
| Nomex Paper |
Class H (180°C) |
Slot insulation |
| Epoxy Resin |
Class F/H |
Motor winding impregnation |
4. Power Electronics Insulation Materials
| Component |
Common Insulation Materials |
| Inverter |
FR-4, Polyimide Film, Silicone Gel |
| DC/DC Converter |
FR-4, G10, Epoxy Resin |
| On-Board Charger (OBC) |
FR-4, Polyimide Film |
| Power Distribution Unit (PDU) |
GPO-3, SMC, Epoxy Resin |
| High-Voltage Junction Box |
SMC, Silicone Rubber |
Mainstream Insulation Materials in NEVs
| Application Area |
Preferred Materials |
| Battery Pack |
Nomex, PI Film, Mica, Aerogel |
| Busbar System |
GPO-3, Epoxy Resin |
| Traction Motor |
NMN, NHN, Nomex, PI Film |
| Power Electronics |
FR-4, Polyimide Film |
| HV Junction Box |
SMC, Epoxy Resin |
| HV Cables |
XLPE, Silicone Rubber, EPDM |
