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

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

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

Messe K-Kunststoffmesse

kunststoffe-international.com

kunststoffe.de

Demonstrator for EV Battery Housings

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

Kunststoffverarbeitung: Verfahren

Kunststoff-Aufbereitung

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

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

Wide Range of PA Innovations

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

Streifinger, Florian

Polymethylmethacrylat

Polycarbonat

Suitable Materials for Smart  Vehicle Design

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

One of the last major German chemical giants, BASF is fighting back against the weak economy with an extensive efficiency program. Its acquisition of Solvay’s polyamide business has strengthened the engineering thermoplastics value chain. The circular economy is providing most of the new impetus.

Fig. 2. The <a href="http://Futurecraft.Loop">Futurecraft.Loop</a> sneaker is a recyclable shoe made from 100 % recycled material

BASF and Its Customers Commit to Chemical Recycling

Forward Together!

The specialty chemicals group has developed a new concept for radar sensors with integrated thermal management. A combination of thermally conductive plastics with metallic cooling elements in hybrid technologyg is used.

The concept for radar sensors provides for heat dissipation from hot spots using thermally conductive plastics in combination with metallic cooling elements

Hybrid-Spritzgießen (Metall / Kunststoff)

Spritzgießen

Radar Sensors with Integrated Thermal Management

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

Lanxess will transfer its High Performance Materials unit to an independent legal corporate structure.

The plastics of the High Performance Materials business unit are used primarily in the automotive, electrical and electronics industries

Kunststoff-Erzeugung

Faserverbundwerkstoffe

Andere Werkstoffe

Herstellung von Gummi und Kunststoffwaren

Kunststoffverarbeitung

Lanxess’ Business Unit to Become Legally Independent

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.

Wirtschaft

Lanxess and Advent to Buy DSM‘s Engineering Plastics Business

Up to now, the relevant interactions between thermoplastics and metal surfaces at the interface have not been fully investigated. In this article, possible intermolecular interactions between plastics and metal surfaces are described and investigated on injection-moulded composite specimens made of polyamide 6 and polybutylene terephthalate with aluminum as a composite partner. The results of the investigation show that the composite adhesion is mainly based on intermolecular interactions between the composite partners and not on mechanical form-fit. If the polar surface of the aluminum is chemically inactivated without changing its surface topography, then no composite adhesion occurs.

Intermolecular interactions through hydrogen bonds between a carbonyl group in polyamide and a metal hydroxide surface.

Hybridwerkstoffe

Aluminium

Metall Werkstoffe

NE-Metalle

Kupfer

Oberflächentechnik

Optische Mess- und Prüfverfahren

Qualitätssicherung

Qualitätssicherung Kunststoff

Intermolecular interactions and their influence on the adhesion between plastics and metal surfaces

The change in drive-train technology from the conventional combustion engine to the electric drive poses a big challenge for car manufacturers and suppliers alike. Engineering plastics have versatile properties that offer a wide potential for applications in electric vehicles.  

From the Prototype of the First Lithium-Ion Battery to Thermoplastics for Electrification 

Energiemanagement / Ladetechnik

Polypropylen

Synergies from the Far East 

For years, the temperature resistance of engineering thermoplastics increased, but now new forms of mobility require a whole range of other properties. Although the exact specifications for plastic components in e-mobility vehicles and infrastructure are still being discussed, the first production-ready material types are already in the starting blocks. 

Semicrystalline Thermoplastics for Electrical and Electronic Components 

Making the Switch with E-Mobility 

The orange RAL 2003 color has established itself as a signal color for high-voltage components in electromobility. Vital for these components is the longevity of the color while at the same time maintaining other properties such as flame retardancy and hydrolysis resistance. Orange compounds based on PBT and PA are now available for high-voltage connectors. Laser marking also provides an essential characteristic to orange-colored components.

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

The automotive industry is undergoing one of its most significant changes: replacing classic combustion engines with electric drive, triggering substantial changes. The entire powertrain (drive) architecture is changing. New components are necessary to safeguard the high-voltage range and establish the connection between the battery and the electric motor. These connectors must meet a wide range of requirements, such as flame retardancy, color stability and electrical properties. The smaller the connector, the shorter the distance between electrical contacts. According to IEC 60664–1, which allows voltages of up to several kilovolts, the smallest contact distance can only be achieved with materials that achieve the highest insulation class 1 with a CTI 600 (Comparative Tracking Index), according to IEC 60112.

BASF has developed exceptional, orange-colored plastic grades, identified as Durable Color, for high-voltage connectors (Fig. 1). This portfolio includes orange-colored Ultradur PBT grades and a wide range of orange Ultramid PA grades. The Ultramid grades are available in aliphatic polyamides (PA66 and PA6) and semi-aromatic PA (Ultramid Advanced)(Table).

Flame-Retardant and Resistant  to Heat Aging

These materials by BASF meet the lowest flame-retardant classification UL 94 HB (Horizontal Burning) and applications that require increased flame retardancy and independent extinguishing after removal of the ignition source, according to UL 94 V-0. Flame-retardant formulations only use non-halogen flame-retardant systems.

Polybutylene terephthalate’s (PBT) very low moisture absorption leads to high dimensional accuracy with stable mechanical and electrical properties simultaneously. This plastic tends to hydrolytic degradation in warm and humid climates. In this case, the molecular chains shorten and the product becomes brittle – hydrolysis-stabilized grades, identified with HR (Hydrolysis Resistance), remedy this tendency. Polyamide (PA), on the other hand, is inherently stable in warm and humid climates and is characterized by increased impact strength.

Suitable Stabilizer Prevents  Contact Corrosion

While polybutylene terephthalate is inherently resistant to heat aging, PA always requires a heat stabilizer because temperatures up to 140 °C can be reached in high-voltage connectors (Fig. 2). Stabilizers with an increased halide content are often used. Although halides can lead to problems such as contact corrosion over their service life, especially in electrical applications, choosing the right heat stabilizer is crucial. All Durable Orange plastics developed by BASF have a total halogen content of &lt; 100 ppm, including the flame-retardant types.

Orange is a clear signal that immediately recognizes which cables and plugs carry high voltage – even after years of use and exposure to the highest temperature stress. The orange color must stand out, and orange components made of PBT comprehensively meet market requirements regarding color stability and are already in serial production.

PA, on the other hand, is a complex case. It turns yellow and brown over time, even if it is orange. In general, stabilization is essential when using PA compounds at elevated temperatures. Otherwise, atmospheric oxygen and high temperatures initiate a thermo-oxidative degradation of the PA, leading to oxidation of the polymer chains, which splits polymer chains in subsequent reaction steps, resulting in the loss of mechanical properties. From a purely visual perspective, this degradation occurs in uncolored compounds, even at low temperatures. A rapidly increasing yellowing or brown discoloration occurs within a very short time.

Initially, this is exclusively a surface phenomenon and only affects a low layer thickness due to the low permeability of oxygen in the polymer matrix. Although pigments help cover the yellow or brown discoloration, this is insufficient in maintaining the initial color. Since stabilization of the PA is necessary so the oxidation processes are suppressed or delayed, a suitable stabilizer system should also have color stability. It should not discolor under light or in combination with moisture.

During the development of the new Durable Orange materials, BASF engineers investigated the stabilization of the base polymer and the influence of other additives such as glass fiber types, lubricants, and pigments. The good mechanical properties of glass fiber-reinforced compounds achieved through the chemical bonding of the polymers to the glass fiber takes place via glass fiber sizing. Glass fiber sizing consists of various organic components such as adhesion promoters, film formers and other auxiliary materials, which themselves can often contribute to yellowing. Due to different sizing formulations, color stability depends on the type of glass fiber. Different lubricants also have a substantial effect on yellowing. Although color pigments and optical brighteners usually help improve color stability, many pigments change color when exposed to temperature stress.

In addition to selecting suitable glass fibers, lubricants, and temperature-stable color pigments, the innovative stabilization package, newly developed by BASF, leads to excellent color stability of orange-colored glass fiber-reinforced compounds. These materials have the suffix DC (Durable Color). (e.g., Ultramid Exp. A3E3G6 DC OR, Fig. 3).”

The traceability and identification of components and more relevant data within the Data Matrix Code (DMC) have become essential. Laser marking is a sustainable, durable, and economical method of imprinting information. A higher contrast leads to improved readability. For this reason, white marking is usually used for black products, while dark marking is best for white products. Since legible marking is challenging for orange products, it is feasible with a suitable additive and laser setting. The product retains its color stability, electrical properties, and the required fire behavior. BASF is further developing materials for laser marking and, for the first time, offers a flame-retardant PA in orange that is laser markable at a wavelength of 1064 nm for dark labeling (lettering) (Fig. 4). Non-flame-retardant variations, as well as corresponding PBT compounds, are also in the developmental phase.

BASF SE  

https://www.basf.com

Ausgabenartikel

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

Fig. 1. In addition to PBT, BASF now also offers PA grades for high-voltage connectors.

Fig. 2. Elongation at break of PA66 Ultramid Exp. 3E3G6 DC OR after heat aging at 120 and 140 °C and PBT Ultradur B4331G6 HR OR at 150 °C. A heat stabilizer was added to the PA to achieve the corresponding values.

Fig. 3. Sample plates from PA66 Ultramid Exp. A3E3G6 DC OR under the influence of heat aging at different temperatures and storage times: The influence of temperature on the color tone is clearly visible.

Fig. 4. Appropriate additives can also be used to lasermark orange polyamides such as PA66 Ultramid Exp. A3U44G6 DC LS OR.  The example shown was created with a laser at 1064 nm.

Table. BASF offers various materials in orange for high-voltage components. 

PIn6-23_BASF - Hauptartikel

Color-Stable and Lasermark Orange for Electric Cars

<ul><li>Patrick Frey has been working for BASF for 10 years and is Segment Manager for E&E in the Performance Materials division.</li><li>Andreas Nixdorf has been with BASF for 11 years. He is currently working as Team Leader in application development for BASF’s Engineering Plastics.</li><li>Dr. Tina Kolb has been working for BASF for 5 years. She is a Product Developer in the field of Research and Development for Ultramid.</li></ul>

Read the German version of the article in our magazine Kunststoffe or at <a href="https://www.kunststoffe.de/a/fachartikel/hoch-spannend-und-orange-4989661" target="_blank">www.kunststoffe.de</a>

<ul><li> Color stability (RAL 2003)</li><li> Flame retardant, up to UL 94 V-0</li><li> Laser marking at wavelength 1064 nm in dark lettering</li><li>CTI 600</li></ul>