MATERIALS | HIGH TEMPERATURE
Above:
Envalior has designed Xytron
M5080ET PPS primarily for EV busbars that must withstand temperatures above 150°C
equipment parts more sophisticated and diverse. While fluoropolymers have dominated the market, tightening PFAS regulations mean that alternatives are needed. The material incorporates Toray’s Nanoalloy
microstructure control technology. It finely dispers- es a new flexible component within PPS polymer to replace elastomers. The material’s flame retardancy corresponds to the V-0 classification of UL94. The material’s heat resistance and lightness surpass the performance levels of conventional flexible PPS resins, it says. This year, Toray started supplying samples to customers for such applications as battery periph- eral and semiconductor manufacturing equipment components. It will establish a mass production structure within fiscal 2026. While complying with PFAS regulations and enhancing functionality, the company will deploy the material for applications that require high temperatures and reliability such as fasteners for electrified vehicles and data centres, and peripheral components for batteries and inverters.
Automotive applications Eurotec says its PPS materials under the Tecotron brand offer greater thermal stability than standard engineering plastics, while maintaining mechanical performance at elevated temperatures. Tecotron also delivers excellent chemical resistance, dimen- sional stability for high-precision parts, and inherent flame-retardant properties, it says. Tecotron XS20 GR40 BK009 is a black PPS
material reinforced with 40% glass fibre. It com- bines high mechanical and impact strength at elevated temperatures with strong chemical resistance and stable electrical properties, making it suitable for a broad range of applications. Showing high strength in short- and long-term thermal tests, good mechanical strength and modulus values, high creep resistance, and stable
28 COMPOUNDING WORLD | August 2026
dielectric properties, Tecotron PPS can be used as a metal replacement in demanding applications. In automotive, applications include under-hood and cooling system components, such as thermostat housings, where resistance to high temperatures and harsh automotive fluids is required. In electri- cal and electronics, suitable applications are connectors, coils and sockets that require long- term mechanical performance and stable electrical properties. Another market is the one for home appliances and white goods, in applications such as fans, pumps, control units, and heating and cooling systems where metal replacement is beneficial. Envalior has developed Xytron M5080ET, a new
PPS reinforced with 50% by weight of a glass fibre-mineral mixture for overmoulding and functionalizing busbars for electric vehicles (EVs). The impact-modified compound is primarily designed for busbars that must withstand tempera- tures above 150°C while also being highly resistant to stress cracking during thermal shock. The company says it developed the compound in response to the trend for rising temperatures in EV powertrains.
“Our compound is developed to ensure that,
throughout the entire service life of the vehicle, the busbars are not impaired in their function by stress cracks and do not cause short circuits that lead to the failure of the entire assembly,” said Arthur Rieb, Business Development Manager at Envalior. In EVs, busbars must safely conduct electricity between the high-voltage battery, control unit, drive, and charging unit. They are made of copper and overmoulded with plastic to provide electrical insulation from the surrounding environment. Envalior said the challenge with such overmoulded components is that the thermal expansion of copper and plastic usually differs significantly, favouring the formation of stress cracks in the plastic during abrupt and frequent temperature changes. With the new Xytron PPS compound, its thermal expansion is closer to that of copper, even perpendicular to the melt flow direction and glass fibre orientation in the part, and this stability is maintained even at high temperatures. This significantly reduces the risk of stress cracks, according to the company. “Tests conducted at Envalior have shown that our new compound exhibits over 70% higher stress crack resistance in thermal shock tests at tempera- tures between -50°C and 180°C compared to similar PPS compounds,” said Rieb. “This is sup- ported by the fact that the weldlines in the compo- nent, which are created by converging melt fronts
www.compoundingworld.com
IMAGE: ENVALIOR
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36
