MATERIALS | HIGH-TEMPERATURE PLASTICS


incorporates frames with a diameter of 85cm. Ultrason enables them to be large, robust, and durable, with a focus on higher operating tempera- tures and longer lifetimesIts stable mechanical properties make it suitable for current (90 °C) and future (>100 °C) electrolysers. Jochen Schmid, of global business development


for Ultrason at BASF, added: “With Ultrason, our customers can upscale green hydrogen production and advance the transformation to clean energy.” BASF’s Ultrason portfolio meets the needs of


AWE and other types of electrolyser, such as proton exchange membrane (PEM), and anion exchange membrane (AEM).


Above: BASF’s Ultrason PSU is being used in the manufacture of alkaline water electrolysers


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.


Right: BASF says its PA66/6T compounds bridge the gap between


conventional PA66 and PPA


Hydrogen economy Estonian electrolyser manufacturer Stargate Hydrogen is using Ultrason polysulphone (PSU) from BASF to make the frames in its stacks used for alkaline water electrolysers (AWEs) – which pro- duce hydrogen from water. The PSU replaces metals such as nickel, resulting in much lighter stacks. This is possible because the material offers high temperature and chemical resistance in harsh alkaline conditions and can withstand high stack pressures. Because it can be injection-moulded, it provides greater design flexibility than metal. “Ultrason combines light weight with outstanding performance, helping us to improve the efficiency and lower the cost of alkaline electrolysers,” said Marko Virkebau, CEO of Stargate Hydrogen. The patent-pending design of the stacks


14 INJECTION WORLD | March/April 2026


High-heat PA66 At the same time, BASF says its portfolio of PA66/6T compounds fills the gap between conven- tional PA66 and polyphthalamide (PPA). It says its Ultramid T6000 outperforms PA66 in mechanical and dielectric properties in humid, high-tempera- ture environments. Its lower moisture absorption ensures good dimensional stability, closing the gap on its own PPA portfolio. Ultramid T6000 allows for easy processing at mould temperatures similar to those of standard PA66. Due to its good colourability, compounds with different white shades can be made, as well as durable orange and grey. The flame-retardant grades use a non-halogenated flame retardant. Good flowability makes it suitable for producing


small, complex E&E components such as high- voltage connectors and miniature circuit breakers (MCBs), and parts in electric powertrains and consumer electronics. Ultramid T6340 G6, for instance, can be used in high-voltage connectors for electric vehicles at elevated temperatures. “Tests have proven that mould temperatures of 90-110°C have no significant influence on its mechanical properties and surface appearance,” said Andreas Stockheim, from PPA business


www.injectionworld.com


IMAGE: STARGATE HYDROGEN/BASF


IMAGE: BASF


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