43 Battery Show USA | Show report E-Mobility Engineering | January/February 2025 solution. The cable design includes a tube that has been modified for this application to insulate coolant from high-voltage components, preventing galvanic corrosion. Dziubek explains: “Heat transfer occurs through this material, maintaining electrical isolation while ensuring effective cooling of the cable.” The use of liquid cooling allows the cable cross-section to be made smaller without compromising performance. A 50 mm2, water-cooled cable can rival the functionality of a much thicker, 250 mm2, uncooled cable. “This can lead to potential weight savings for vehicles, as thinner cables can replace larger, heavier ones,” he notes. In terms of additional features, the CCS2 inlet retains standard functionalities, such as AC/DC charging and robust communication systems. It includes safety mechanisms, such as a locking pin to secure the connector during charging and optional indicator lights to show the charging status. “We can also integrate heating units to prevent freezing in cold climates or de-icing through the vehicle’s existing thermal-management system,” Dziubek says. This indicates a change in direction by Amphenol Tuchel towards supplying solutions such as this, rather than just components, with a focus on being a problem-solver for OEMs. Amphenol’s design is still in early development. Preliminary prototypes are undergoing testing, with timelines for production tools estimated at six to nine months after the design is finalised. Fullscale production is anticipated within a year, depending on customer interest. Avery Dennison discussed its new high-voltage-resistant FT-0031 dielectric tape, launched as part of the Volt Tough EV battery portfolio. Avery Dennison’s Scott Krusinski describes the FT-0031 as a “second-generation” product that builds on the initial Volt Tough designs to address specific challenges in modern EV applications. He says the new iteration achieves significant improvements in dielectric strength, conformability and tear resistance. One of the tape’s standout properties is its dielectric strength of over 11 kV, supported by a durable acrylic adhesive, which “provides high shear strength and heat resistance”, ensuring it can endure for the lifespan of a battery pack. This high-performance adhesive bonds to metal components; an essential feature given the tape’s primary role in insulating areas of high electrical potential across complex metal surfaces. The FT-0031’s conformability is another defining attribute. Krusinski says the tape incorporates a proprietary, elastic film that is capable of “stretching over 600% before it rips”, making the performance of BEVs, and further developing hybrids, which are increasing in popularity once more. “I’m seeing now that, locally, many car dealers are having trouble keeping hybrids on the lot.” Continuing development of EV technology through difficult times is particularly important if US and European manufacturers are to remain competitive with the Chinese, he says. “If we just sit back, and wait and see, we’re going to find that the Chinese are going to be leading in so many categories that it’s going to take a tonne of tariffs to stop them.” Meanwhile, companies that exhibited in Detroit continue to develop innovations to address these issues, at least from a technological standpoint. What follows is a sampling of products designed to speed up manufacture, enable higher charge rates, refine thermal management, improve safety and reliability through more secure connectivity, and provide better protection from shorts and electromagnetic interference. Amphenol Tuchel Electronics presented its innovative, liquidcooled power inlet for EVs that accept combined charging system (CCS2) connectors, with the purpose of enhancing high-rate charging capabilities, reducing charging times, and improving system efficiency while ensuring safety and reliability. “We’ve designed a water-cooled loop within the CCS2 inlet to aid heat dissipation from the inlet, enabling higher current transfer,” says Amphenol’s Greg Dziubek. “This allows EVs to charge faster, reducing the time to charge significantly and moving closer to the convenience of refuelling gasoline vehicles in minutes.” The system integrates with existing EV cooling systems, using the same fluids and thermal-management loop as the battery. Amphenol has also partnered Gebauer & Griller to integrate their water-cooled cables with its CCS2 Amphenol’s liquid-cooled, onboard-charger inlet connector and cable (Image courtesy of Amphenol)
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