Electric Powertrain

Electric powertrain systems face unprecedented demands as the automotive industry accelerates toward higher voltages, faster charging, and greater efficiency. At the heart of these challenges are three critical applications: busbar insulation, hairpin wire insulation, and slot laminates for high-voltage motors. These components must withstand extreme electrical stress, intense heat, mechanical vibration, and harsh environmental conditions.

These challenges can compromise the entire drivetrain, reduce electric vehicle (EV) performance, and create significant safety hazards. For example, electrical arcing and short circuits can trigger system failures or fires. Corona discharge in high-voltage systems such as 800V motors can degrade insulation, leading to electrical breakdown. Mechanical vibration can loosen connections, while moisture, dust, and temperature extremes can shorten motor lifespan and reduce reliability.

Advanced polyimide films from Qnity offer high dielectric strength and corona resistance and are engineered for use in demanding high-voltage applications. Their superior thermal stability enables effective heat dissipation, reducing the risk of thermal runaway. These films also provide flexibility and resilience protecting against mechanical stress and vibration, while their environmental sealing capabilities protect against moisture and contaminants that could degrade performance.

As electric powertrains become more compact and powerful, the demand on insulation materials will intensify. Next-generation architectures – including 800V+ systems and ultra-fast charging capabilities – require materials that can perform reliably under even more extreme conditions. Through global research and development initiatives, Qnity continues advancing materials innovation to meet these challenges. By enhancing dielectric strength and thermal conductivity, improving corona resistance, while withstanding harsh mechanical and environmental conditions, Qnity’s materials portfolio empowers design engineers to meet the needs for reliable electric powertrain performance and drive innovation forward.