MATERIALS | HIGH TEMPERATURE PLASTICS
Below: Solvay has introduced a Xydar LCP material for high-heat EV battery module insulation
tardant engineering thermoplastics and provide mechanical stability at temperatures far above the melting point of a standard PA66, says Ascend, which sees potential for use managing thermal runaway conditions in EV battery systems. Starflam- X is available in unfilled, 30% glass and 60% glass/ mineral filled grades, all with a glow wire flamma- bility index (GWFI) temperature of 960°C as well as a UL94 V-0 rating at 0.8 mm wall thickness. The glass-filled grade has an R22:HL3 rating for interior components, according to European railway safety standard EN 45545. In direct flame exposure testing at 1,100°C, moulded samples of Starflam X-Protect with a wall thickness of 3mm withstood the entire test duration of 15 minutes, compared to less than four minutes for 3mm aluminium and less than three minutes for 3mm standard flame-retardant PA66. Similar increased levels of integrity are useful in next-generation industrial power management systems, metal- welding applications, lead-free soldering process- es and electrical components where arcing can occur. X-Protect shows good flow and can be mould- ing under similar process conditions and on the same equipment as standard polyamides. It can also be coloured in bright shades such as the signal orange used for high voltage EV compo- nents. Ascend says Starflam also delivers good aesthetic surface quality in combination with improved abrasion resistance and better ultrasonic weldline strength over conventional PA66. Earlier this year, Solvay announced the intro- duction of a new high-heat and flame retardant addition to its Xydar liquid crystal polymer (LCP) portfolio, designed to meet safety demands in EV battery components. The new Xydar LCP G-330 HH material addresses thermal and insulation require- ments and is targeted at battery module plates operating in higher voltage systems. “As automakers are moving from 400V to 800V
on next-generation electric vehicles, new regula- tions in Europe, China, the US and other countries are increasing the demand on battery components to withstand temperatures from 300°C to 1,000°C for an extended window of up to 15 minutes,” says Brian Baleno, Head of Marketing, Transporta- tion at Solvay Materials.
“Appropriate materials are expected to retain a level of electrical insulation protection that will provide
sufficient time for passengers to exit the vehicle in a thermal runaway event. Our new Xydar LCP
38 COMPOUNDING WORLD | August 2023
Right: Celanese materials are used in this wireless EV charging system from VMAX New Energy
grade combines this high safety potential with exceptional processability.” Xydar LCP G-330 HH is a glass-filled LCP capable of retaining its electrical insulation upon exposure to temperatures of 400°C for 30 minutes. It is an inherently flame retardant polymer, eliminat- ing the need for halogen or bromine additives, and offers good flow that helps designers achieve thinner parts than possible with incumbent battery module insulation materials.
Tackling noise Japan’s Kuraray says, compared to competitive products, its Genestar PPA offers improved chemical resistance and lower moisture absorption, which makes it a good choice for use in applica- tions such as coolant control valves and thermal management applications. With noise reduction being an area of increasing scrutiny as the EV revolution takes hold, Genestar PA9T is also available in unreinforced grades offering good NVH performance along with high dimensional stability and good wear resistance. “Electronic applications in EVs are targeted with
Genestar’s HB and V-0 grade portfolio, which can reach voltages up to 950V with an enhanced CTI test set-up, dielectric strength around 30 kV/mm and a volume resistivity of 1E+10 Ω.cm,” says Laurent Hulpiau, Advanced Sales Engineer Gen- estar PA9T. “All three of these properties are reduced only slightly after conditioning (high moisture, high temperature) compared to other P(P)As and combining this with a good colour stability and reflow capability makes it possible to use Genestar in high voltage (connector) applica-
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IMAGE: CELANESE
IMAGE: SOLVAY
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