LANXESS develops colored polyamide connector cable harnesses for electric vehicles

Cable harnesses are one of the most complex components in an electric vehicle
.
Not only must its numerous connectors be colour-coded to indicate a range of functions and support assembly and maintenance, but they must also be flame-retardant and mechanically stable
.
Through the use of the polyamide 6 compound Durethan BKV30FN04, LANXESS has developed a material that has been tested in a wide range of applications, including in cable harnesses for electric models produced by a European and American car manufacturer
.

"Compared to polyamides protected with red phosphorus, our halogen-free flame retardant compounds can also be dyed in bright, vibrant colours such as orange (RAL 2003) and yellow," says Bernhard Stoll, specialist in plastics use for electrical and electronic components at LANXESS
.
The compound exhibits a high degree of thermal stability, which means that different connectors can be easily and correctly distinguished over the entire service life of the vehicle
.
" The connectors are produced by Amphenol- Manufactured by Tuchel Electronics
.

Pre-colored compounds reduce costs

LANXESS' polyamide 6 compounds achieve a V-0 rating in the UL 94 flammability test (test body thickness: 0.
75 mm)
.
“We have UL’s yellow-card listed compounds in a full range of colors, including yellow, orange and blue
.
This means processors don’t have to color the product themselves or go through the time-consuming UL certification process
.
They Our pre-colored compounds can simply be used as is, which helps cut costs
," says Stoll
.

The cable harness runs the entire length and width of the vehicle and corresponds to all the different on-board power lines for electrical and electronic functions such as power converters, battery charging systems, electric drives and infotainment systems
.
The total length of the cables can reach several kilometers, which is one of the reasons why cable bundles are so heavy
.
The complexity of cable bundles makes them very expensive components, which is why the connectors cannot be disconnected during installation
.
"Our compound is very strong, which means the connector can withstand bumps or drops," Stoll said
.
Thermoplastics are highly resistant to chemicals, so their strength and stiffness are hardly affected by exposure to electrolytes or coolants
.
It also exhibits good tracking resistance, achieving a CTI of 600 under orange (Comparative Tracking Index, IEC 60112)
.