#Japan #Tokyo #electric vehicles #Sumitomo Bakelite #Insulation Sheet

Innovative 0.2mm Insulation Sheet from Sumitomo Bakelite

Sumitomo Bakelite Co., Ltd., based in Shinagawa, Tokyo, has announced the development of a pioneering 0.2mm insulation sheet that is resistant to tracking. This advanced product responds to the increasing demands for safety and miniaturization in electrical applications, particularly in electric vehicles (xEV) and high-voltage industrial equipment. The innovative insulation material is poised to enhance safety without compromising on thickness.

Background: The Shift to High Voltage Systems

As electric vehicles (EVs) gain traction, the demand for electrical power increases significantly. This growing power requirement has led to a shift towards high-voltage systems, particularly those operating at 800 volts. However, this transition comes with challenges, including increased heat generation due to high output, necessitating compact and lightweight designs. Engineers have long struggled to balance the need for safety with the pursuit of thinner insulation materials. The introduction of this new insulation sheet opens the door to solutions that address both issues effectively.

Key Features of the New Insulation Sheet

The newly developed insulation sheet features a thickness of only 0.2mm, a benchmark for the industry. It utilizes PFAS-free and non-halogen flame-retardant formulations to ensure environmental compliance without compromising performance. This insulation is rated for high-temperature environments and offers excellent tracking resistance for voltages up to 800V. Future plans include customer evaluations using provided samples, alongside strategic market entry.

Specifications and Performance

• - Tracking Resistance: Capable of withstanding 800V, offering superior performance compared to traditional materials.
• - Flame Retardancy: Rated as UL94V-0, this product maintains a high standard of fire safety even at its minimal thickness.
• - Temperature Resistance: Continuous use temperature rated at a remarkable 140°C, allowing for versatility in high-stress applications.

Applications of the Insulation Sheet

This innovative insulation technology is well-suited for critical components in electric vehicles, including:

• - On-Board Chargers (OBC)
• - Drive Inverters
• - DC/DC Converters
• - Insulation for Lithium-Ion Battery (LiB) systems

Additionally, it finds applications in industrial machinery, serving as insulation for high-voltage power supply units and auxiliary devices that support high-voltage operations.

Versatility in Processing Techniques

Sumitomo Bakelite’s new insulation sheet, based on their established polycarbonate series, is compatible with various manufacturing processes such as punching, bending, and vacuum forming. This adaptability allows for remarkable flexibility in design, meeting diverse customer requirements. The reduction in thickness not only promotes lightweight assembly but also improves spatial efficiency in high-voltage applications in both vehicles and industries.

Future Prospects

This insulation sheet represents a threefold achievement in addressing safety, lightweight construction, and environmental considerations. It is designed to meet the rising demands of a smart society with increasing electrical power requirements. The company aims to accelerate product development and market entry, targeting an annual sales goal of 1 billion yen.

Upcoming Exhibition

Sumitomo Bakelite will showcase this innovation at the 18th International Car Electronics Technology Exhibition, scheduled from January 21 to 23, 2026, at Tokyo Big Sight, West Hall W6-12. With a theme centered on "Creating New Value through Plasticization," the exhibition will highlight technological advancements across four domains: electrification, miniaturization, driving support, and environmental impact. Attendees are encouraged to visit the booth to witness this cutting-edge product firsthand.

Contact Information

For inquiries regarding this product, please reach out to:
Sumitomo Bakelite Co., Ltd.
Industrial Functional Materials Sales Division
Tel: 03-5462-8700
Inquiries Link