AUTOMOTIVE | COMPOUNDS
Above and right: As ranges extend, EVs must now work with even higher operating voltages
systems are also evolving. Quick connectors traditionally made of PA66 GF can be replaced by Altech NXT PP, which is characterised by good recyclability, lower density, and suitability for 2K injection moulding, according to Mocom. The same applies to cooling water pipes. Mocom says it aims to offer a range of viable alternatives, such as flexible Alfater XL TPV lines, a recyclable replacement for EPDM rubber with lower greenhouse gas consumption. Envalior’s latest range of compounds for e-mobility applications, to be displayed at K2025 later this year, includes several innovations targeted at the changing needs of automakers. “As EV ranges extend while charging times go down, electric vehicles must now work with even higher operating voltages of up to 800V and above,” said Tim Arping, Director of Segment Innovation and Advanced Development at Envalior. “This places greater demands on the materials used in e-powertrains, meaning they have to meet higher specifications in terms of electrical and tracking resistance. Envalior’s R&D capabilities focus on developing optimised solutions for the future of e-mobility, taking a comprehensive approach to material development that considers the needs of the entire system.” The company’s compounds address specific
application requirements while maintaining processing efficiency for high-volume production. “Materials for high-voltage connectors, for example, must not only offer high and stable electrical performance, good dimensional stability, and safe flame retardancy, but also prevent electrochemical corrosion, avoid ionic migration, and provide robust mechanical properties to survive thermal cycling and other ageing effects
24 COMPOUNDING WORLD | August 2025
over the entire lifetime of the vehicle,” continues Arping. “In collaboration with global automakers and their major suppliers, we’ve tailored our R&D and production capabilities to maximise innovation efficiency, material quality, and customer value.” Envalior says its tracking-resistant, hydrolysis- stabilised, and heat-resistant compounds maintain exceptional safety and reliability performance, even as operating voltages rise and component creepage distances may be further reduced. This enables components to accommodate increasingly complex system architectures, supporting a higher integration density to allow for smaller, lighter, and more sustainable product designs.
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Strength and resistance Among Envalior’s recent e-mobility developments are Xytron PPS grades to support robust e-powertrain components, a new
Pocan PBT grade for high-voltage connectors, the high-CTI Pocan E
portfolio for e-mobility applications and Stanyl PA46 for high-speed bearings. The
company’s latest material, Pocan BFN4221Z, is reinforced with 20%-by-weight short glass fibres giving it a high elongation break of 2.9% (ISO 527-1,-2) and good Charpy impact strength (ISO 179/1eU) of 45 kJ/m². It says components made from the new material are more resistant to cracking, and the material is particularly resistant to thermal shock making it ideal for overmoulding metal components that are exposed to rapid and large temperature changes. It is also significantly more resistant to tracking with a stable Comparative Tracking Index (CTI) of 600 (IEC60112). Envalior says it also addresses evolving
regulatory requirements through its range of PFAS-free flame retardant options, ensuring proactive compliance and reduced regulatory risk, and offers specific solutions for hybrid, hydrogen- powered, and battery EVs, supported by resilient supply chains and local compounding capabilities that ensure continuous material availability. At the Battery Show North America in Detroit last October, Celanese highlighted its latest advancements in engineered material solutions for EVs, focusing on safety, efficiency and sustainability. One material showcased was Zytel HTN FR53G50NH, a high-temperature polyamide designed for battery module end plates and other structural components which offers superior stiffness, reduces warpage, and improves noise, vibration, and harshness performance, all while
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IMAGE: ENVALIOR
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