Improving the performance of high voltage connectors in electric vehicles with MOLYKOTE® speciality lubricants

To ensure optimum adhesion, it is essential to prepare the surface of the materials to be bonded prior to application.

With this in mind, Samaro and its partner Socomore recommend the use of Diestone DLS. This chlorinated hydrocarbon-free cleaner and degreaser evaporates quickly, ensuring perfect surface preparation for effective adhesion.

As electric vehicles (EVs) continue to gain ground in the automotive industry, the importance of high-voltage connectors cannot be overstated. These connectors play an essential role in the smooth operation of an electric vehicle. One of the main challenges facing these connectors is moisture ingress, which can lead to electrical problems and reduced reliability. To overcome this, good sealing and consistent electrical conductivity are essential. MOLYKOTE®, a renowned brand specialising in lubrication solutions, offers a range of specialist lubricants designed to meet these challenges and ensure the reliability of high voltage EV connectors.

Sealing performance: MOLYKOTE® 111 compound and MOLYKOTE® HP-300 grease

To maintain the functionality of high-voltage connectors, elastomer seals are commonly used to prevent moisture from entering the system. However, these seals require effective lubrication to prevent micro-cracking during assembly and to simplify the assembly process. MOLYKOTE® 111 Compound and MOLYKOTE® HP-300 Grease have been developed to meet these specific needs.

• MOLYKOTE® 111 Compound: This lubricant is compatible with a wide range of plastics and elastomers. Its excellent water resistance effectively prevents moisture penetration. It has minimal vapour pressure and volatility, with only 0.8% evaporation by weight after 30 hours at 204°C. This means it remains effective in high-temperature environments, making it ideal for high-voltage connectors.
• MOLYKOTE® HP-300 Grease: Like MOLYKOTE® 111 compound, this grease is compatible with a variety of plastics and elastomers. It offers superior resistance to chemicals and solvents, including water. With high temperature resistance up to 250°C, it can withstand extreme conditions. In addition, it has high dielectric strength and arc resistance, making it a reliable choice for sealing performance.

Electrical conductivity: MOLYKOTE® L-8030 semi-dry lubricant

The metal pins of high-voltage connectors require effective lubrication to maintain constant electrical conductivity over time. MOLYKOTE® L-8030, a semi-dry lubricant, is the solution to this problem. It offers a number of advantages, including

• Good compatibility: MOLYKOTE® L-8030 is compatible with a range of plastics and elastomers, ensuring that it will not compromise the integrity of connectors.
• Non-sticky: After application, it does not become sticky, ensuring smooth and efficient operation.
• Super thin layer: This lubricant forms a super thin, transparent lubricating layer, minimising fretting and fretting corrosion caused by vibration and protecting metal from oxidation.
• Consistent performance: Field tests have shown that MOLYKOTE® L-8030 semi-dry lubricant maintains constant friction values over 250 assembly cycles, with no change in electrical conductivity.

Specifications and technical data

To ensure the reliability of high-voltage EV connectors, here are some key properties of MOLYKOTE® lubricants:

• Dielectric strength: MOLYKOTE® 111 compound and MOLYKOTE® HP-300 grease offer high dielectric strength, which is essential to maintain electrical performance even in high voltage environments.
• Prevent formation of electrical arcs: Both lubricants prevent arcing, so they can withstand electrical stresses without degrading.
• Compatibility: These lubricants are compatible with a wide range of materials, including plastics, elastomers and metals.

Conclusion

In the ever-expanding world of electric vehicles, the reliability of high-voltage connectors is paramount. MOLYKOTE® speciality lubricants, such as MOLYKOTE® 111 compound, MOLYKOTE® HP-300 grease and MOLYKOTE® L-8030 semi-dry lubricant, are designed to meet the unique challenges faced by high voltage connectors. These lubricants not only prevent moisture penetration but also ensure consistent electrical conductivity, making them invaluable in the quest for reliable and efficient EV performance.