Browse
Log in / Register
Share
April 10, 2025 – As automakers accelerate the shift toward low-global warming potential (GWP) refrigerants, Sensata Technologies has launched a dedicated R290 (Propane) Pressure + Temperature (P+T) Sensor to support the adoption of R290 in electrified vehicle thermal management systems. The sensor addresses critical safety, leakage, and accuracy requirements that have become central to next-generation EV HVAC and heat pump designs.
With the European Union moving to phase down HFC refrigerants under the F-Gas Regulation, and the U.S. Environmental Protection Agency proposing tighter restrictions on high-GWP refrigerants in automotive applications, R290—a natural refrigerant with a GWP of 3—is gaining traction among OEMs exploring PFAS-free and low-GWP alternatives. However, R290’s flammability (A3 classification) introduces strict leakage control requirements that demand precise, real-time monitoring of pressure and temperature.
Sensata’s new sensor integrates both pressure and temperature measurement in a single package optimized for R290 systems. The design aims to reduce refrigerant loss over the vehicle’s lifetime, helping OEMs meet regulatory leakage thresholds while improving thermal system efficiency. According to the company, the sensor delivers response times and accuracy levels necessary for safe operation in battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and other electrified platforms.
Markus Schwabe, executive vice president & president of Automotive at Sensata Technologies, noted that the industry is navigating a fundamental shift in refrigerant technology. “Customers are evaluating new chemistries and system architectures to comply with evolving environmental and performance standards. Our R290 P+T sensor provides the reliable sensing data needed to adopt R290 with confidence,” he said.
The sensor’s leakage-optimized construction is a critical differentiator. Unlike conventional sensors designed for non-flammable refrigerants, the R290 P+T sensor features sealing and material choices that minimize propane leakage over the vehicle’s lifespan. This is especially important as OEMs face proposed U.S. EPA rules under the American Innovation and Manufacturing (AIM) Act that could cap refrigerant leakage rates in mobile air conditioning systems.
Industry analysts note that while R290 has been widely used in stationary heat pumps and commercial refrigeration, its adoption in automotive thermal management is still in its early stages. A 2024 report from the International Institute of Refrigeration estimated that R290 could capture up to 15% of the global automotive refrigerant market by 2030, driven by regulatory pressure and OEM commitments to net-zero goals.
However, the transition is not without challenges. R290 requires specialized system components, including compressors, heat exchangers, and sensors capable of handling its unique properties. Sensata’s sensor is designed to integrate seamlessly with existing thermal management architectures, reducing the need for extensive redesign. The company claims the sensor’s robust construction ensures reliable performance across the harsh automotive environment, including vibration, temperature extremes, and exposure to contaminants.
The new sensor also supports enhanced system diagnostics. By providing real-time pressure and temperature data, it enables more precise control of HVAC and heat pump cycles, improving energy efficiency in EVs. This is critical as automakers seek to extend driving range in cold climates, where heat pump performance significantly impacts battery consumption.
Sensata is positioning the sensor not only for passenger cars but also for commercial electric vehicles, off-highway machinery, and stationary energy storage systems that use R290. The sensor is available now for sampling, with production volumes expected to ramp up in the second half of 2025.
Sensata’s move comes as several major automakers, including Volkswagen and Tesla, have publicly expressed interest in R290 for future EV platforms. In 2024, Volkswagen announced a pilot program to test R290 in its MEB platform, citing potential cost savings and environmental benefits. The German automaker stated that R290 could reduce refrigerant-related CO2-equivalent emissions by over 90% compared to current R134a systems.
The sensor’s key features include:
As OEMs finalize their refrigerant strategies for the 2026–2028 model years, accurate sensing will be a linchpin for safe and efficient R290 adoption. Sensata’s new sensor offers a ready-made solution that could accelerate the industry’s transition away from high-GWP gases.
