Burst and Contact Protection for Power Electronic Components in Electric Vehicles
Customized Protective Sheath for Safety-Critical Components in High-Voltage Systems
Power electronics and high-voltage (HV) systems place special demands on vehicle safety in electromobility. Components carrying high voltages must not only function reliably during normal vehicle operation. Even under mechanical stress or in the event of a crash, the risk of contact with live components must be minimized.
To meet these challenges, Frenzelit develops customized protection solutions for power electronics and HV components. Textile protective sheaths made of high-strength, coated aramid combine burst protection and contact protection with exceptional mechanical strength and electrical insulation. Each solution is tailored to the component, the available installation space, and the specific safety-related and regulatory requirements of the respective vehicle application.
Do you have a power electronics component with special protection requirements?
Together, we develop the right material and component solution for your application, from the initial concept through to a series-ready component.
Burst and Contact Protection as Part of HV Safety
In the event of an accident, power electronics components as part of the high-voltage system may be mechanically damaged. Even when the vehicle safety systems respond, individual power components may initially remain energized.
This is where additional burst and contact protection for power electronics components comes into play: a suitable protective sheath creates an additional barrier between the live component and its surroundings.
Depending on the application, the protection solution can fulfill various functions:
- Contact protection against live components
- Mechanical burst and penetration protection
- Electrical insulation
- Additional protection for occupants and emergency responders in the event of a crash
- Resistance to temperature, moisture and other environmental influences
- Integration into complex component geometries and confined installation spaces
Material, design and manufacturing are tailored to the specific HV application.
thermoREFLEX® Protective Sheath: Protection to the Highest Standard
With thermoREFLEX®, Frenzelit offers a textile material solution for the burst and contact protection of high-voltage components.
A thermoREFLEX® protective sheath developed for a DC/DC converter demonstrates how such a solution can be implemented in practice. A precisely manufactured aramid fabric encloses the component and creates an additional barrier against live parts.
The high tensile strength of the aramid fabric simultaneously provides mechanical protection and can help prevent debris from penetrating the textile sheath
One Protective Sheath – Multiple Protective Functions
 | Contact Protection The textile covering creates an additional barrier between the HV component and its surroundings. |
 | Burst Protection The high mechanical strength of the aramid fabric supports the protective effect even under severe mechanical stress. |
 | Electrical Insulation A special coating on the aramid fabric provides high dielectric strength. |
 | Durability Material and coating can be designed for demanding automotive operating conditions. |
Practical experience Protective sheath in the Audi e-tron
Frenzelit developed the thermoREFLEX® textile aramid protective sheath for the DC-/DC converter in the electric SUV Audi e-tron.
Technical Facts
Technical Properties of the Implemented thermoREFLEX® Protective Sheath
The requirements for burst and contact protection go far beyond purely mechanical encapsulation.
Material:
High-strength aramid fabric
Mechanical protection:
High tear and cut resistance
Electrical insulation:
High dielectric strength through specially coated aramid fabric
Insulation resistance:
10 MΩ, even after various aging processes
Weather resistance:
UV- and moisture-resistant coating
Media resistance:
Resistant to automotive media such as oils
Design adaptation:
Customized design with integrated cutouts for power cables, cooling lines and mounting points
Tested under Automotive Conditions
During the development of the implemented protective sheath, the solution was subjected to a range of validation tests, including:
- Climate cycling test
- Climatic resistance test
- Salt spray test
- Chemical resistance testing
- High- and low-temperature storage testing
- Thermal shock testing
- Humidity testing
Important: The specific technical properties of a customized protection solution depend on the component, installation situation and requirement profile.
Did you know?
Frenzelit develops not only technical textiles but also sealing solutions for electromobility. Discover additional products and applications.
Power Electronics Systems Have Different Requirements
Installation space, component geometry and operating loads vary from one application to another. In addition, requirements regarding electrical insulation, mechanical strength, temperature resistance, media resistance and integration into the overall system can differ significantly.
For this reason, Frenzelit's expertise is not limited to a specific material or an existing protective sheath.
The key lies in combining material expertise, engineering know-how and manufacturing competence.
This makes it possible to develop a customized protection solution based on a specific technical challenge.
Different geometry?
The protective sheath can be tailored to the component's contour and the available installation space.
Different mechanical requirements?
Material design and component construction are engineered to meet the specific performance requirements of the application.
Different electrical requirements?
The material and coating system can be adapted to achieve the required level of electrical insulation.
Challenging environmental conditions?
Temperature, humidity, exposure to media and other environmental influences can be taken into account during material selection and component design.
New HV application?
Frenzelit works closely with you to identify the optimal material and design solution for the required protection functions.
Material Expertise for More Than One Application
The implemented protection solution for a DC/DC converter is only one example of what is possible with thermoREFLEX®.
Wherever HV components require protection, electrical insulation or mechanical shielding, technical textiles and insulation materials can provide the basis for an individual solution.
The key question is not: “Is there an existing protective sheath that fits my component?”
Instead: “What material and protection solution does my component require?”
Frenzelit answers this question together with development engineers, designers and project managers in the automotive industry.
Explore our customized sealing and corrosion protection solutions here:
Do you have a power electronics component with special protection requirements?
Whether burst protection, contact protection, electrical insulation or a combination of different protective functions: Talk to Frenzelit about your specific challenge.
Together we develop a solution tailored to your component and operating conditions, from the first idea through to a series-ready solution.
Your Component. Your Requirements. Our Material Expertise.