MATERIALS | HIGH TEMPERATURE THERMOPLASTICS
In direct flame exposure testing at 1,100°C, moulded samples of Starflam X-Protect with a wall thickness of 3 mm withstood the entire test duration of 15 minutes, compared to less than 4 minutes for 3 mm aluminium and less than 3 minutes for 3 mm standard flame-retardant PA66. Similar increased levels of integrity are useful in next-generation industrial power management systems, metal-welding applications, lead-free soldering processes and electrical components where arcing can occur. X-Protect exhibits good flowability for moulding under similar process conditions and on the same equipment as standard polyamides, and can be coloured in bright shades like signal orange. It also delivers aesthetic surface quality in combination with improved abrasion resistance and better ultrasonic weldline strength than conventional PA66. Furthermore, a recent study has confirmed the material’s recyclability. In March, Solvay announced the introduction of a new high-heat and flame retardant grade in the company’s Xydar liquid crystal polymer (LCP) portfolio, which is designed to meet safety de- mands in EV battery components. The new Xydar LCP G-330 HH material addresses thermal and insulation requirements and is targeted at battery module plates operating with higher voltage systems.
Brian Baleno, Head of Marketing, Transportation
Below: Solvay has introduced a Xydar LCP material for high-heat EV battery module insulation
at Solvay Materials, says: “As automakers are moving from 400V to 800V on next-generation electric vehicles, new regulations in Europe, China, the US and other countries are increasing the demand on battery components to withstand temperatures from 300°C to 1,000°C for an extend- ed window of up to 15 minutes. Appropriate materials are expected to retain a level of electrical insulation protection that will provide sufficient time for passengers to exit the vehicle in a thermal runaway event. Our new Xydar LCP grade com- bines this high safety potential with exceptional processability.” Xydar LCP G-330 HH is a glass-filled LCP capable of retaining its electrical insulation upon exposure to 400°C for 30 minutes. It is an inherently flame retardant poly- mer, without the use of halogen or bromine
additives, and offers exception- al flowability helping designers
achieve thinner parts than possible with
incumbent battery module insulation materials. Kuraray says Genestar, a new PPA developed
48 INJECTION WORLD | April 2023
Right: Celanese materials are used in this wireless EV charging system from VMAX New Energy
from “unique monomers”, offers additional proper- ties including good chemical resistance and low moisture absorption, making it ideal for use in applications like coolant control valves and thermal management applications. With noise reduction being an area coming under increased scrutiny as the EV revolution takes hold, Genestar PA9T also has unreinforced grades in its portfolio with high dimensional stability, a low NVH property and good wear resistance. Laurent Hulpiau, Advanced Sales Engineer Genestar PA9T, says: “Electronic applications in EVs are targeted with Genestar’s HB and V-0 grade portfolio which can reach voltages up to 950V with an enhanced CTI test set-up, dielectric strength around 30 kV/mm and a volume resistivity of 1E+10 Ω.cm. All three of these properties are reduced only slightly after conditioning (high moisture, high temperature) compared to other P(P)As and combining this with a good colour stability and reflow capability makes it possible to use Genestar in high voltage (connector) applica- tions and power module parts like IGBTs and bobbins.”
High performance
With the acquisition last November of the engi- neering plastics division of DuPont, Celanese expanded its range of solutions to include more materials for applications requiring high tempera- ture stability. Richard Chang, Market Manager E&E at Cela-
nese, says: “If you consider the classic plastics pyramid, we now offer solutions from the very top of the temperature range, LCP and PPS, for
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IMAGE: CELANESE
IMAGE: SOLVAY
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