Viton™ Fluoroelastomers for High Voltage EV Cables
The global EV cable market is projected to grow rapidly due to US government incentives (such as consumer tax credits), investment in EV charging infrastructure, and OEMs investing in electrifying their automotive fleet. The Infrastructure Investment Act is poised to contribute over $7 billion toward building a nationwide network of EV charging stations. With such a large investment in electrifying the US automotive industry, OEMs are researching and developing EVs that drive longer on a single charge through high-voltage power cables.
To meet design and regulatory standards, EVs must maintain lightweight features while handling the long distances consumers demand from their vehicles. High-voltage power cables are utilized for an EVs electrical system, as they carry the high-voltage direct current (DC) power from the battery pack to the motor and power electronics. These cables are exposed to extreme temperatures and harsh chemicals, such as battery acid, which could cause them to degrade over time.
The nominal system voltage used for these vehicles is between 600 volts alternating current (VAC) (900 volts direct current [VDC]) to 1,000 VAC (1,500 VDC). This means automotive power cables will transition to bigger-diameter cables to support the investment in higher-voltage systems.
Viton™ is known for its excellent resistance to high temperatures, chemicals, and fuels. It is often used in applications in the automotive and aerospace industries that require high temperature and chemical resistance, such as seals and gaskets in fuel injection systems. But e-mobility technology can also benefit from Viton™ fluoroelastomers by insulating and sheathing high-voltage power cables.
High Voltage Cable with Viton™ Insulation
Viton™ Fluoroelastomer Benefits
Viton™ fluoroelastomers are high-performance products that offer extruders and compression and injection molders the following benefits for EV high-voltage cables:
Extreme temperatures: can operate continuously exceeding 200ºC for long periods
Chemical resistance from battery electrolyte, engine oil, and transmission fuel
Low permeability to a broad range of chemicals
High-pressure performance that meets larger-diameter high-voltage requirements
Superior durability to protect from harsh chemicals, heat, and mechanical properties
Enhanced mechanical properties, such as tear strength, elongation, and tensile strength
Viton™ Electrical Properties
Viton™ fluoroelastomers used in high-voltage EVs offers volume resistivity and dielectric strength. With mineral filled Viton™ compounds can reach a volume resistivity > 1013 Ohm*cm. While exhibiting dielectric strength above 20 kV/mm.
Stress/Strain, original @23ºC (cured 10 min @177ºC + oven 24 hrs @ 232ºC )
100% modulus, MPa
Tensile @ break, MPa
Elongation @ break, %
Hardness, durometer A
Dielectric Strength, Kvolts/mm
Breakdown Voltage, KV
Filler system: BaSO4 30phr
Electrical properties obtained on slabs 0.635 x 152 x 152 mm (0.025 x 6 x 6 in)
Viton™ Fluoroelastomers EV Applications
Viton™ can be cured through bisphenol and peroxide systems, where cross-linking occurs due to heat and pressure. It can also offer dielectric strength exceeding 20 kV/mm, depending on the compound recipe, filler system, and curing conditions. For large-diameter high-voltage cable manufacturing, Viton™ helps with processability and flexibility. EV components consist of very sensitive, small, and lightweight requirements, and Viton™ can be applied to the following insulations:
Viton™ fluoroelastomers are suitable for high-voltage power cable insulation in electric vehicles due to their excellent resistance to high temperatures and chemicals. As the demand for EVs continues to grow, Viton™ usage in high-voltage power cables is likely to become more widespread in the automotive industry. Talk to a specialist today about how Viton™ can improve your EV high-voltage cable formulations.