HIGH TEMPERATURE PLASTICS | MATERIALS
new formulations in its Fortron PPS range. The new “T” formulations provide excellent thermal shock resistance combined with high electrical insulation properties and outstanding flame retardance, with a UL rating of V-0 at 0.8 mm. Celanese offers numerous materials suitable for busbar overmoulding including PBT, PA, PPA and PPS, with grades formulated to provide exceptional mechanical properties, oil resistance, heat resist- ance and electrical properties. The company offers extensive design support to ensure material selection. In addition to testing, Celanese has designed an algorithm that helps guide decisions on what the appropriate component design would be, so customers do not have to invest so much time on trial-and-error prototyping. The company has commissioned hundreds of successful simula- tions and conducts a ‘strain over life’ analysis as part of its design support. In the area of battery sealing and insulation rings for lithium-ion batteries Celanese said the chal- lenge of the sealing rings is to prevent moisture of contaminants from entering the battery cells, which could compromise its performance or cause safety hazards such as thermal runaway or short-circuits. The materials typically used offer good chemical resistance to electrolytes, electrical insulation, and mechanical properties (TS> 50Mpa@ break 30%) and can maintain their integrity across a range of temperatures in different manufacturing processes and use environments. Celanese offers formulations based on PBT and
PPS, with each material delivering a different mix of properties to meet a variety of design and manu- facturing processes. For example, its Fortron PPS formulations address higher chemical, tempera- ture, and moisture resistance needs, while its Crastin PBT offers toughness and moisture resist- ance, and can be an economical replacement for PP if mechanical strength and higher durability is needed, said Flöck. Ascend Performance Materials says that in the
world of internal combustion engines, materials marked for under-the-hood components around the engine are benchmarked at temperatures around 130° C and 150° C for lifetime estimates between 3,000 to 5,000 hours. In today’s electric vehicles, some components see temperatures between 120° to 150° C but the lifetime expec- tancy can be considered at about 10,000 hours. High temperature materials must function instanta- neously at these elevated temperatures but also maintain properties through the lifetime of the components, which in EV terms are composed of drive cycles and charging cycles, said Ian van
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Duijvenboode, Senior Director for Mobility. Ascend said that as the demand for EVs contin- ues to rise so does the need for advanced materi- als that can meet the unique performance require- ments of electric drivetrains, power distribution, thermal management, and interior components.
Beyond automotive Developments in high temperature plastics also cater to applications outside of the automotive sector, such as the Internet of Things, where the number of connected devices continues to proliferate, leading to increased demand for materials that can withstand constant connectivity, environmental exposure and rigorous usage, said Steve Manning, Senior Director for Engineered Materials. Data centres, considered the backbone of the digital economy, are also under constant pressure to increase efficiency, reduce energy consumption and scale rapidly to meet the needs of an ever-expanding user base. Power manage- ment devices, circuit protection, high voltage connectors and cable management systems will continue to increase the demand for innovative engineered materials.
Ascend said it has made advances in its Starflam
X-Protect family of PA66 compounds, which is capable of withstanding direct exposure to flame imparting temperatures up to 1,100° C for 15 minutes, mitigating the risk of a thermal runaway to EV passenger safety. The material combines flame retardancy with structural integrity, making it a candidate for fire barriers, be it as an enclosure material or electrical insulator for components like busbars. The fire resistance of Starflam X-Protect has been demonstrated in an abstract, specimen base test as well as pragmatic component testing. Starflam X-Protect recently passed a safety test for EV battery enclosure materials High performance polymers differ from standard
September 2024 | COMPOUNDING WORLD 55
Above:
Busbars are an application area being targeted by Celanese
IMAGE: CELANESE
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