Insulation Materials Used in New Energy Vehicles（NEVs）

Time: 09-22 2025 Auther: Xujue Electrical

Insulation Materials Used in New Energy Vehicles New energy vehicles (NEVs) involve high-voltage battery systems, dr...

Insulation Materials Used in New Energy Vehicles

New energy vehicles (NEVs) involve high-voltage battery systems, drive systems, and control systems, which require insulation materials with high thermal resistance, dielectric strength, flame retardancy, mechanical strength, and lightweight properties. The commonly used insulation materials are as follows:

1. Battery System Insulation Materials

Battery insulation paper/film: Aramid paper (Nomex), polyester film (PET), polypropylene (PP), polycarbonate (PC), used for cell-to-cell and module insulation.

Battery insulation boards: Epoxy glass cloth laminate (FR4 sheet, G10 sheet, G11 sheet), PP honeycomb board, PC board.

Battery pack thermal management insulation: Ceramic-coated insulation sheets, thermally conductive insulating silicone pads.

2. Motor and Drive System Insulation Materials

Motor winding insulation: Polyimide film (PI), polyester film (PET), composite insulation paper (DMD, NMN).

Slot insulation and slot wedges: G10/G11 epoxy glass laminate, aramid paper, DMD paper.

Impregnation materials: Epoxy resins, polyester resins for motor winding impregnation and curing.

Wire insulation: Enameled copper wire (PEW, AIW, EIW, etc., high-temperature enameled wires).

3. High-Voltage Distribution and Control System Insulation Materials

Busbar insulation: Epoxy boards, heat shrink tubing, insulation coatings.

High-voltage connectors and harnesses: Cross-linked polyethylene (XLPE), fluoropolymers (PTFE, FEP), silicone rubber jackets.

Insulation sleeves and parts: Heat shrink tubing, cold shrink tubing, insulating sleeves.

4. Thermal Management and Safety Protection Materials

Flame-retardant insulation materials: Flame-retardant PP, flame-retardant PC, flame-retardant nylon (PA66 + GF).

Thermal insulation materials: Ceramic fiber paper, mica board, aerogel insulation materials.

Phase-change and thermal barrier composites: Applied for battery pack thermal runaway protection.

Insulation Materials for New Energy Vehicles – Comparison Table

Material Category	Typical Materials	Application Areas	Key Performance Requirements
Insulation Paper / Film	Aramid paper (Nomex), PET film, PI film, PP film	Battery module separators, motor winding interlayer insulation, ECU isolation	High dielectric strength, heat resistance (≥200℃), flame retardancy, dimensional stability
Composite Insulation Paper	DMD (non-woven–PET–non-woven), NMN (aramid–PET–aramid)	Motor slot insulation, interlayer insulation of windings	Thermal class F/H, good flexibility, high dielectric strength
Laminated Boards	FR4, G10, G11 epoxy glass cloth laminates	Battery insulation boards, motor slot wedges, HV busbar supports	High mechanical strength, dielectric strength, flame retardancy, moisture resistance
Wire Insulation	Enameled wires (PEW, EIW, AIW, PIW)	Motor winding conductors	High temperature resistance (155–240℃), dielectric strength, solvent resistance
Impregnation Materials	Epoxy resins, unsaturated polyester resins, PI varnish	Motor winding impregnation & curing	Enhanced insulation, moisture resistance, heat resistance, improved mechanical strength
HV Cable Insulation	XLPE, PTFE, FEP, silicone rubber	High-voltage cables, wire harnesses, connector jackets	High dielectric strength, chemical resistance, flame retardancy, flexibility at low temperatures
Busbar Insulation	Epoxy coating, insulation boards, heat shrink tubing	High-voltage busbars	High dielectric strength, flame retardancy, wear resistance
Thermal & Safety Insulation	Mica board, ceramic fiber paper, aerogel blankets	Battery thermal runaway protection, thermal barriers	Flame retardant, high temperature resistance (>1000℃), thermal insulation
Flame-Retardant Plastics	Flame-retardant PP, flame-retardant PC, flame-retardant PA66+GF	ECU housings, connectors, structural parts	Lightweight, flame retardant, high mechanical strength, aging resistance
Functional Composite Materials	Ceramic-coated insulation sheets, thermal conductive silicone pads, PCM phase change materials	Battery pack thermal management, module insulation	Thermal conductivity + electrical insulation, flame retardancy, thermal runaway protection

Summary:

Battery System → Aramid paper, FR4, thermal conductive insulating pads, aerogel

Motor System → DMD, NMN, enameled wires, epoxy resins, G10 slot wedges

Control System → XLPE/PTFE cables, epoxy insulators, flame-retardant plastics

Safety Protection → Mica boards, ceramic coatings, PCM phase change composites

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