Electronic – Is the 42V car dead

automotive

I was rather curious about why many buck converters and linear regulators were rated up to 42V, or close to it. It's a rather strange voltage to stop at, after all – why not 40V or 45V?

I read that it was due to an idea in the late 90's to early 2000's where every car was going to use a 36V lead acid battery (which would have a peak charging voltage of 42V.) A higher voltage means smaller wires. And cheaper high-end stereo systems as 36V can drive loudspeakers louder and they can have higher impedances. And smaller, cheaper motors. And a few other things.

However, the idea died down because a lot of car manufacturers already had a large inventory of 12V parts and accessories and didn't want to change them. Additional issues were found with making relays compatible with 42V due to arcing and contact wear.

Yet I still see parts being made with 42V ratings. Why? Just a throwback to the old days? Is there another industry that uses 42V?

Best Answer

I was rather curious about why many buck converters and linear regulators were rated up to 42V, or close to it. It's a rather strange voltage to stop at, after all - why not 40V or 45V?

It's because of something called safety extra-low voltage (SELV) -- certain regulatory standards allow voltages up to 60V under all conditions, and other ones allow up to 50V. (Unfortunately I can't find any references to standards, and even if I did, you wouldn't be able to view them for free. :-( ).

When you consider a 42V nominal automobile battery under worst-case conditions (load suddenly going away during charging), it can be higher than 42, so there's enough margin to stay below 50V and be able to pass those regulatory standards.

Above the ELV/SELV limits, you can operate but you have to use different connectors, make sure there's no exposed parts that are energized at that voltage, etc. -- so there's a quantum jump of expense and difficulty that starts at that point.