MATERIALS | HIGH TEMPERATURE PLASTICS
IMAGE: BASF
grade achieves an electrical RTI value of 150° C. The properties of the new Ultramid Advanced N
grade support the miniaturisation of IGBTs by lower creepage distance and better insulation than materials so far used for these power switches, BASF said. The IGBTs function as a fast and efficient switch in high-power electrical circuits and can be assembled as modules, enabling applications characterised by an increase in voltage current while becoming more compact, the company said. The compound is optimised to withstand increasing temperatures and higher electrical currents while maintaining its mechanical strength and protects the semi-conductors against mechanical and environmental stress like humidity, dust and dirt. BASF said manufacturing IGBTs with its PPA
Above: BASF says the properties of its new Ultramid Advanced N grade support the miniaturisa- tion of IGBTs by lower creepage distance and improved insulation
Its Romitron PPS line, which includes standard
glass fibre or mineral-filled grades or blends and compounds reinforced with specialty fillers or additives, help users meet their requirements for high temperature operation and other functions. Romira developed a new Romitron EXP3178
grade with close to 35% weight reduction com- pared to a standard PPS GF/M65 grade. It also offers Romitron EXP3159 that contributes EMI protection along with a high flammability rating of V-0 at 0.8 mm thickness. Several EV parts need EMI protection over different frequencies, such as battery and electronics housings, infotainments enclosures, as well as ADAS and LiDAR housings, the company said.
Good for IGBTs BASF says that manufacturers of high-performance power electronics are seeking materials that enable reliable power management in electrical compo- nents and miniaturisation, which is in line with increasing user requirements for energy savings, weight reduction and application downsizing. Outstanding chemical resistance, dimensional stability and high thermal stability are a require- ment in applications for high-speed railways, solar and wind energy, and smart manufacturing, said Ulla Biernat, Communications for Performance Materials, Specialty Polymers and PPA at BASF. BASF is now offering Ultramid Advanced N3U41
G6 LS, a tailored polyphthalamide (PPA) especially suited for manufacturing housings of insulated- gate bipolar transistor (IGBT) semi-conductors. The new Ultramid Advanced N grade is a laser sensi- tive, non-halogenated flame-retardant compound that combines higher thermal stability with low water uptake and electrical properties character- ised by a CTI greater than 600 V. The UL-certified
54 COMPOUNDING WORLD | September 2024
material is compatible with potting materials used to assemble the semi-conductors after injection moulding with metal pins and clamps. Its PPA portfolio includes Ultramid Advanced N (PA9T), Ultramid Advanced T1000 (PA6T/6I), Ultramid Advanced T2000 (PA6T/66), Ultramid T KR (PA6T/6, Ultramid One J (PA66/6T) and Ultramid D3 (PA/ PPA). The PPA portfolio includes more than 50 compounded grades, with or without flame retardants, and available in different shades from colorless to laser-markable black, with short-glass, long-glass, or mineral fibre reinforcement and with various heat stabilisers.
Busbar applications Celanese says that the overmoulding of a thermo- plastic onto metal in a busbar application for electric vehicles has always been a challenge and the requirements for these components are becoming increasingly stringent. In addition, lithium-ion battery sealing and insulation rings for EV battery components, used to prevent leakage of electrolytes and to insulate the battery components to maintain safety and performance, are also a chal- lenge, said Joachim Flöck, Celanese Senior Automotive Marketing Manager. When it comes to busbars, thermal shock testing is intense. The component is placed in a climate chamber that cycles between extreme cold (-40° C) and extreme heat (150° C), with the overmoulded thermoplastic required to remain solidly attached to the copper busbar with no cracks due to the stress of the temperature changes. “During operation in an EV, cracks in the insulative thermo- plastic could increase the risk of thermal runaway and could even cause short-circuit induced fires,” Flöck said. The company recently expanded its portfolio of busbar overmoulding materials with the addition of
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