Thinner Gauge Dielectric Film for Capacitors of Hybrid, Plug-in-Hybrid, and Battery Electric Vehicles

A new, thinner gauge version of Elcres HTV150A dielectric film from SABIC is targeted to capacitors in the traction inverters, onboard chargers and electrical compressors of hybrid, plug-in hybrid and battery electric vehicles (xEV). The new 3-micron film is reportedly 40% thinner than SABIC’s 5-micron film launched a year ago, enabling further volume and weight reductions and greater design flexibility through enhanced energy density for the capacitor.

Like the 5-micron Elcres HTV150A film which is based on PEI, the new exceptionally thin film (SABIC will say only that it’s based on an engineering thermoplastic), is said to maintain stable performance at high operating temperatures up to 302 F/150 C and addresses the critical performance gap experienced by traditional polypropylene (PP) films above 275 F/135 C. This new level of thermal performance helps customers to increase the adoption of SiC power modules with smaller package size due to the higher energy density, reducing weight while providing the increased efficiency and performance desired for increased xEV adoption by consumers.

Elcres HTV150A dielectric film is reportedly the first capacitor film in the industry to be engineered for stable performance at operating temperatures of -40 F/C to 302 F/150 C and frequencies up to 100 kHz, while offering stable capacitance, high insulation resistance and good dielectric performance (dielectric constant—Dk of 2.9, dissipation factor--Df of 0.002). Other key properties include high breakdown strength over the full temperature range, good self-healing and excellent adhesion to aluminum and zinc. The film has been validated by customers for use with both film-foil and metalized electrodes. Capacitors built with 3-micron and 5-micron metalized films pass standard electrical and life tests at 302 F/150 C for 2000 hrs. with low capacitance change and stable insulation resistance.

Said Greg Stoddard, technical director of SABIC’s Resins and New Chemistries, “When we launched the five-micron Elcres HTV150A last year, we committed to develop thinner gauges to meet requirements for different capacitor voltages – and we’ve delivered on that pledge. Our new three-micron film can help customers design smaller package sizes that potentially avoid the use of active cooling systems associated with films that perform at lower temperatures. As OEMs design electric and hybrid vehicles to operate at specific voltages, the new three-micron film can help with differentiation by providing tailored properties. Segmentation of voltage performance aids automakers to match capacitor performance to the needs of different vehicles in their product lines.”