HIGH TEMPERATURE PLASTICS | MATERIALS
other countries which increase safety requirements on battery components to withstand temperatures from 300° C to 1,000° C for an extended window of up to 15 minutes. The new glass-filled LCP grade can retain its electrical insulation properties upon exposure to 400° C for 30 minutes. Syensqo said Xydar LCP G-330 HH is an inherently flame-retardant polymer without the use of halogen or bromine additives. It offers exceptional flowability which allows battery designers to achieve thinner parts than possible with incumbent battery module materials, such as polycarbonate or aerogels. The company said it has successfully injection moulded test plates that insulate the battery module and end plate or between each prismatic battery cell, with typical dimensions of 100 by 150 by 0.5 mm. This material grade can also drastically reduce the thickness in the production of slot liners which are incorporated into the rotor design of an electric drive traction motor. “Customers can now choose between PEEK films or LCP injected slot liners, where both technologies are designed to reduce the size of the insulators and increase the thermal conductivity, ultimately increasing the overall efficiency of the e-motor,” the company said. The grade is produced using recycled glass fibres and 100% renewable electricity.
Advanced properties Syensqo also expanded its Ryton polyphenylene sulphide (PPS) portfolio with a high-voltage and a high-flow grade, developed to perpetuate signifi- cant leaps in automotive electrification. “OEMs and Tier 1 suppliers in automotive are constantly seeking ways to improve safety, reliability and sustainability without compromising system cost efficiency,” the company said. Its high-voltage Ryton PPS Supreme HV grade, specially developed for High Voltage Power Modules, combines a CTI of 600 V in electrical performance while maintaining its continuous use temperature (CUT) or electrical thermal index (RTI) above 175° C for superior heat resistance with UL94 V0 flammability ratings, the company said. Its new Ryton HF high-flow grade has been designed for bobbins in axial flux motors. It offers high mechanical strength and excellent flowability for 0.3 mm thin-walled components, which can reduce the temperature of the heating element, facilitating reliable thermal management. In the case of coil carriers, a lower thickness allows for better thermal exchange, which can help to better manage the temperature of the motor. A reduced wall thickness also allows for more copper in the
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component, which can mean a higher efficiency of a system, Syensqo said. Target applications where the material can make a significant contribution to miniaturisation and package optimisation include bobbins for stators and insulators. Romira sees new applications in electric vehicles as the driver behind increased demand for polymers with higher thermal and electrical properties. In addition, other features including electromagnetic interference (EMI) shielding and thermal/electrical conductivity are getting more attention. In hybrid electric vehicles, downsizing of the combustion engine leads to local hot spots which thermal management systems need to be designed to manage.
Thermal management Specifically, Romira said that to meet the demand for high voltage parts, polymers with higher levels of flame retardancy and comparative tracking index are needed, along with increased heat/thermal shock resistance. Parts such as invertor and electric motor cores, housings, and capacitor cases need to deliver excellent heat cycle performance. The higher demand for thermal management systems requires materials able to support addi- tional components such as traction motors which have an operating temperature of coils up to 190° C, lithium-ion batteries and high-power electronic controllers, for example. Compared to components used in an internal combustion engine, hybrid EVs feature items like cooling pumps for the batteries and the electric motor that stay in use not only when driving but also during charging cycles, which extends coolant exposure time. “Therefore, polymers with a higher level of chemical resistance are required” Romira said.
� September 2024 | COMPOUNDING WORLD 53
Above: Romira is targeting its Romitron PPS materials at EV applications
IMAGE: JUICE UNSPLASH
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