Why HFFR Matters for Cables in New Energy Vehicles?
Created on 12.02
With electric cars becoming more common, safety is a big deal. One thing that really matters, but people don't always think about, is what kind of insulation is used on the wires. HFFR (material that doesn't have halogen and won't catch fire easily) is becoming super important for new energy vehicle cables, especially the high-voltage ones. This blog post will look at why HFFR is important, how it's being used in new energy vehicles, and what's next for this technology.
Why HFFR is Essential for Cables in New Energy Vehicles?
1. The LSZH Advantage
HFFR is similar to LSZH (Low Smoke Zero Halogen) materials because they both try to cut down on toxic and corrosive fumes if there's a fire. LSZH (or LS0H) coverings don't release many halogens when they get hot.
Halogens, such as chlorine, bromine, and fluorine, can create really corrosive hydrogen halides when they burn.
On the other hand, HFFR stuff doesn't use those elements. This really lowers the chance of acid gases that could wreck equipment or hurt people if a fire breaks out in a small space.
In NEVs, where space is limited and strong systems are close to delicate electronics, lowering corrosive emissions can keep parts safe if there's an accident or the system overheats.
2. The High-Voltage and Thermal Runaway Risk
Electric cars use high-voltage systems, which can cause electrical problems like shorts or insulation failing. If these things happen, the lithium-ion batteries can overheat very fast, leading to fires or explosions.
When a battery overheats, flames can spread quickly, and the heat makes things worse. HFFR materials can help prevent this because they stop flames without creating dangerous halogen gases.
Moreover, some HFFR compounds are engineered specifically for EV applications, able to achieve high flame-retardancy ratings (like UL‑94 V‑0) even in technical polymers such as polyamides used around battery busbars.
3. Regulatory and Industry Drivers
EV safety rules, like ISO 19642 for high-voltage cables, require strong insulation, flame resistance, and long-lasting performance. The need to meet high heat standards (T4/150°C and above) means we need better HFFR systems, like Cross-Linked Polyolefin (XLPO-HFFR).
Also, chemical companies are creating better halogen-free, flame-retardant formulas made for EV plastics (like phosphorus-based HFFRs) to meet environmental rules and performance needs.
This push comes from more than just the rules. Car companies and their suppliers are using HFFR in wiring, connectors, and charging stations because of safety, emissions rules, and to gain consumer confidence.
HFFR Application in New Energy Vehicles
1. Battery Pack Internal Wiring and Harnesses
Inside the battery pack, there’s a dense network of wires, busbars, resin, adhesives, and structural components. According to EV fire safety research, HFFR is used on polyamide insulations for busbars to maintain flame retardancy under the stress of high voltage.
Additionally, some potting resins or adhesives used to bond cells or fill gaps are flame-retarded via HFFR to maintain integrity during cell failure.
2. High-Voltage Powertrain and Charging Lines
HV cables that run from the battery to the motor or power electronics must not only withstand high electrical stress but also respond safely in fire or fault conditions. HFFR jacketing helps achieve those properties while limiting toxic outputs.
In designing the outer sheath of such cables, HFFR compounds provide a balance between flame retardance, mechanical toughness, and flexibility—critical for dynamic routing within the vehicle.
These cables also need to pass vertical flame tests (like VW-1), which some HFFR formulations can meet.
3. External Charging Cables (The Dynamic Environment)
Charging cables face repeated flexing, outdoor exposure, thermal cycling, and mechanical stress. To be viable, they need a jacketing that is flame-retardant, UV-resistant, and halogen-free.
HFFR materials designed for flexible jacket compounds enable these high-performance cables, reducing risk during abuse or fault. These formulations can also meet UL or other rules for how well they resist fire and how much halogen they contain. This makes them a safer option for charging equipment that's easy to get to. The main thing we need to figure out is how to keep them super bendable and working well, even when it's cold, without losing that fire protection.
HFFR Technical Hurdles and Material Innovations
1. The Performance Paradox: Dielectric Strength vs. Filler Load
One problem with HFFR is that the stuff that makes it fire-resistant, like aluminum hydroxide, can mess with how well it blocks electricity or how bendy the plastic is.
Cable makers have to find the right formulations so the insulation can handle a lot of electricity and still not catch fire easily. It's not simple, especially for cables made for electric vehicles.
2. Balancing Flexibility, Mechanical Strength, and Temperature
EVs demand high bendability (small bending radius), mechanical robustness (to resist vibration), and thermal resilience. Some HFFR compounds used in EV HV cables are engineered to be ultra-flexible (similar to silicone), yet strong enough to resist tearing.
Chemical innovations also help: certain polymers like EVM and HNBR, when compounded with halogen‑free flame retardants, deliver broad temperature range performance (e.g., –50 to 150°C) without sacrificing fire safety.
3. Manufacturing and Cost Efficiency
HFFR compounds are more complex (and often more expensive) than traditional halogenated materials. The high viscosity from heavy filler loads makes high-speed automotive extrusion difficult.
Material suppliers and compounders are working on more efficient formulations—for instance, using phosphorus-based HFFR for EV thermoplastics to reduce cost while maintaining UL rating. A big problem compounders have to deal with is making sure the very active HFFR particles spread almost perfectly throughout the polymer. If they don't mix well, the material will be weaker, won't resist electricity as well, and will have flaws on the surface, which is why the quality of the raw HFFR material is so important.
Conclusion
If you’re ready to take your cable safety—especially for new energy vehicle applications—to the next level, partner with Favorchem! As a leading manufacturer of advanced halogen‑free flame retardants, we offer R&D‑driven, eco‑friendly solutions engineered for high-performance, high-voltage systems. Whether you need technical data sheets, tailored formulations, or product samples, our expert team is here to help. Contact us now!
FAQs
1. How is HFFR different from regular PVC or FR materials?
Unlike PVC, which gives off nasty stuff like corrosive hydrogen halides (HCl/HBr) and thick smoke when it burns, HFFR makes less smoke, isn't as toxic, and doesn't have any halogen in it. That means it meets LSZH (Low Smoke Zero Halogen) standards.
2. What standards around the world say we need HFFR in NEV cables?
Some important standards are:
- ISO 6722 / ISO 19642 (for car wires)
- LV 216 (German standard for high-voltage cables)
- UL94 V-0 & VW-1 (tests to see how easy things catch fire)
More and more, these standards say we have to use HFFR or LSZH materials for high-voltage stuff.
3. Is HFFR good for the environment?
Yep. HFFR doesn't have any halogen, makes less smoke that's not as toxic, and you can recycle it. Plus, there's new HFFR stuff made from plants that makes EV cable manufacturing even better for the environment.
4. How does HFFR make passengers and electronics safer in NEVs?
HFFR cables stop fires from spreading and cut down on toxic smoke, which helps:
- Get passengers out safely
- Keep sensitive electronics from getting corroded
- Stop damage to batteries and other important parts.
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