Electromobility in particular, but also many other electrical applications, are asking for ever higher demands regarding the electrical properties of thermoplastics. This raises the question of whether the polymers commonly used in this area can still meet these demands. The plastics manufacturer, Lanxess, has now investigated how suitable, for example, polyamide and polybutylene terephthalate are for use at higher voltages and temperatures.

16:9

How Suitable Are PA and PBT for High-Voltage Applications?

Polybutylenterephthalat

Kunststoff Werkstoffe

Thermoplaste

Elektronik

Elektromobilität

Mobilität

Polyamide

Leistungselektronik

Technische Kunststoffe

Against the Current

Ascend Performance Materials will focus on electromobility and sustainability at K. The company made this announcement at a press conference in advance of the trade show.

Elektromotoren

Antriebe

Messe K-Kunststoffmesse

kunststoffe-international.com

kunststoffe.de

Wide Range of PA Innovations

Special plastics are needed for the increasingly widespread 800 V drives of electric cars. Bio-based PPA, for example, represents a sustainable option.

Faster and More Sustainable Charging

Orange has become the signal color of electromobility. Compounds based on PBT and PA are now available for high-voltage connectors.

In electromobility, orange is the color of choice, especially for high-voltage components.

Highly Exciting and Orange!

PA66 and PBT considerably expand the field of applications for laser sintering by showing better properties than classic PA11 and PA12 materials in most cases.

As a temperature-resistant and flame-retardant material with high mechanical properties, PA66 opens up new application possibilities for laser sintering, such as its use as a sensor holder

PA66 and PBT for Laser Sintering

Selektives Lasersintern von Kunststoff, Metall, Keramik

Verfahren für die additive Fertigung

Pulverbettverfahren

Kunststoff

Bauwesen

Baustoffe

Additive Fertigung

From Injection Molding to  Additive Manufacturing

DSM sells its Engineering Polymers business to Lanxess and the financial investor Advent. In return, the two companies are setting up a joint venture to which Lanxess is also contributing its PA and PBT business.

Lanxess is outsourcing its engineering plastics business to the joint venture.

Streifinger, Florian

Wirtschaft

Lanxess and Advent to Buy DSM‘s Engineering Plastics Business

The transformation from the combustion to the electric engine entails several imponderabilities for the plastics industry. In part, electric drives have completely different material requirements which are becoming specifically evident with the increasing use of appropriate vehicles.

In electric vehicles, the change in engine technology also entails new requirements for the plastic materials used

Flame Retardancy, Heat and Tracking Resistance of Electric Vehicles

Kfz-Elektronik

Kunststoffe

Photonik

Optik

Elektronische Bauelemente

Hochleistungskunststoffe

Drivers of Electromobility

Electrical architecture in an E-car is significantly more challenging than for conventionally powered vehicles. Particularly for insulation of high-voltage (HV) components, the demands on the materials used are increasing. With specially-tailored materials for electric vehicles, challenges in automotive high-voltage technology can be overcome.

Insulation of high-voltage components in electric vehicles makes high demands on the materials used

Polyamide Specialties for Electromobility

Automotive

High Voltage in Cars

Electric-vehicle makers looking for fresh impetus are turning to thermoplastics, as these can be used to  improve the safety, performance and sustainability of the vehicles. Initial application areas for manufacturers can be found in a multitude of components ranging from battery cases to busbars, cooling lines and seals. Things become very interesting when material suppliers offer support in the form of CAE and injection molding analyses.

Thermoplastics play an important role in the batteries of electric vehicles. They help to keep battery temperatures in the optimal range for a long service life and high performance. 

Improving the Performance of Electric Vehicles with the Right Materials

Electric, Environmentally Friendly, Thermoplastic

The conditions in electric vehicles place high demands on the materials used. Therefore, automakers and suppliers must resort to expensive, high-performance plastics. For many applications, cost-effective alternatives are plastics whose properties have been greatly improved by means of treatment with high-energy electron beams.

Fig. 1. Crosslinked engineering plastics can be used for many different applications in electric vehicles.

Irradiation Crosslinking Replaces High-Performance Plastics with Cheaper Polymers

Strahlenvernetzung

Kunststoffverarbeitung: Verfahren

Kunststoff-Aufbereitung

Electron Booster for Electric Vehicles

With the change from internal combustion engines to hybrid and electric vehicles, peak operating temperatures have dropped from 135 °C to 110 °C. At the same time, the number of operating hours compared to combustion engines has increased nine-fold. This has an influence on material selection.

A Comparison of PA66 and PPA for Electric Vehicles

Higher Performance in Water

Electric vehicles can be charged not only at charging stations, but also wirelessly. Here, the energy exchange takes place between an induction coil positioned in the ground and a receiver coil mounted in the e-car.

Wireless charging could increase the range, and therefore the acceptance of electromobility.

Flame Retardant Polyamide for Inductive Charging Systems

No Cable thanks to Suitable Compounds

Due to the climate change, new fields of development and sustainability topics have come into focus along the added-value chain.

Polyamide continues to be one of the most important technical plastics in the automotive sector, where it enjoys widespread use. This not only applies for classical internal combustion vehicles, but in terms of volume will also be the case for electric vehicles.

Polyamides: Electromobility and Sustainability Boost Developments

Kunststoff-Recycling

Dual Change with Polyamides

The global market for PBT has recovered well from the aftermath of the corona pandemic. However, there is a lot going on among manufacturers at the moment.

PBT compounds are very much in demand for electromobility, including for parts of the battery, electric transmission and the charging infrastructure.

Polybutylene Terephthalate (PBT): Demand for Products with Added Benefits

Electromobility and Sustainability Are Driving Growth

At K 2022, it was clearly shown that with suitable materials not only can CO2 emissions be reduced, but also advantages in component design achieved.

The Japanese chemical company Asahi Kasei showed its concept vehicle at K 2022. The domed roof in particular could lead to a few changes in future automobiles.

With suitable materials CO2 emissions can be reduced and advantages in component design can be achieved.

Automotive Highlights of K 2022

Thermoplastische Elastomere

Silikone

Kunststoffe, biobasiert

Biokunststoffe

Polymethylmethacrylat

Polycarbonat

Suitable Materials for Smart  Vehicle Design

A focal point of the Lanxess booth at the show this year will be materials for electromobility.

A focal point of the Lanxess booth at the show this year will be materials for electromobility. These include a halogen-free, flame-retardant, hydrolysis-stabilized PBT compound that possesses very good electrical characteristics.

Plastic components in electric vehicles are often exposed to higher temperatures and at the same time very strong currents and voltages. Components such as high-voltage connectors must remain electrically insulating under these conditions and must not allow creepage current to occur. Lanxess claims that its compound meets the necessary requirements.

The plastics manufacturer will also be exhibiting a near-series-production demonstrator of a battery housing that was developed in collaboration with Kautex Textron. This is intended to illustrate the fact that high-voltage battery housings for electric vehicles can be designed and manufactured from engineering thermoplastics. According to the company, the demonstrator is a sophisticated, large-format all-plastic housing part. The goal of this development was to demonstrate the advantages of plastics over metals in terms of weight and cost reduction, functional integration and electrical insulation behavior.

Driver Assistance Systems and Sustainability

Alongside materials specifically targeting electromobility, Lanxess will showcase compounds for driver assistance systems. These are widely employed in modern vehicles and are set to become even more important in the future. The plastics producer will be presenting PBT and PA compounds for the corresponding radar sensors and their housings. The company says that these meet the necessary technical requirements on, e.g. radar transparency and dimensional stability, laser welding behavior and mechanical properties for fastening the sensors securely.

Developments in sustainable materials such as plastics and composite materials based on recycled or bio-based raw materials will also be a prominent feature on the company’s booth. Lanxess has announced, for example, the imminent market launch of a matrix plastic based on PA6 for the company’s Tepex dynalite fiber-reinforced plastic, more than 80 % of which is constituted by sustainable raw materials.

LANXESS Deutschland GmbH  

The demonstrator of a near-series- production housing for electric vehicle batteries is one of the highlights at  the Lanxess booth.

For fiber-reinforced composites, Lanxess has developed a matrix material, 80 % of which consists of sustainable raw materials.

2022-09-20 - Lanxess

issue 09/2023

issue 08/2023

issue 07/2023

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