MATERIALS | ENGINEERING THERMOPLASTICS
Covestro collaborates with X2F
On its stand at K2022, Covestro showed the results of a collaboration with X2F, to develop a thermally conductive automotive heat-sink with in-mould electronics using X2F’s controlled viscosity moulding technology. Application samples include small modules for automotive forward lighting. X2F says the new product “will be a unique alternative for automotive OEMs and proces- sors who seek a replacement for cast aluminium heat-sinks that is both lighter and more affordable.” A heat-sink moulded in Makrolon PC is approximately half as heavy as the typical aluminium part. It is part of
an in-mould assembly that can be used to integrate LED modules directly into the headlamp housing – eliminating the weight and labour associated with the installation of
brackets, screws, thermal pastes, and adhesives. X2F says the technology is production-ready; it has already been demonstrated in high-volume series manufacturing for other applications. “This new program involves using
controlled viscosity moulding by X2F to attach the LED module directly onto the thermally conductive heat-sink without fundamen- tally changing the heat-sink adjuster module design,” says
Paul Platte, Senior Marketing Man- ager with Covestro in the USA.
Left: A thermally conductive automotive heat-sink with in-mould electronics using X2F’s controlled viscosity moulding technology
batteries, with stable electrical properties up to 170°C. All grades are designed to achieve UL94 V-0 at 1.5 mm. “The fact that these materials achieve flammability at 1.5 mm rather than 0.8 mm enables them to retain additional performance properties,” the supplier says. Applications range from high voltage connec-
tors, battery modules, and bus bars to junction boxes, inverter parts, and electric motor parts. Certain grades are available in a high-voltage orange colour that remains stable over a broad temperature range.
On the SABIC stand was the Lucid Air EV from
Lucid Motors, said to be the world’s longest-range and fastest-charging luxury production EV. It uses thermoplastics from SABIC in more than 25 applications, including a battery module housing, into which the electrical conductor is incorporated during injection moulding with a 20% glass reinforced flame retardant Lexan polycarbonate (see more information about suppliers working with Lucid Motors in the Automotive feature starting on page 41). Use of metal for the same part would add signifi- cant weight, limit design freedom and
Left: Battery module housing for the Lucid Air EV in SABIC Lexan polycarbonate
32 INJECTION WORLD | November/December 2022
introduce significant processing challenges, says SABIC. Lanxess launched the Pocan E range of PBT glass
reinforced compounds with very high tracking resistance, said to be ideal for compact electrical and electronic assemblies. Grades are available with “excellent” hydrolysis stability, flame-retardant properties, flowability, and toughness. The new compounds score the best possible
rating of 600 in the CTI A test (IEC 60112). “Previ- ously, glass-fibre-reinforced PBT compounds with such high tracking resistance were not readily available on the market. We have now closed that gap,” says Claudia Schmid-Daehling, who shares the responsibility for PBT product development at Lanxess. “The Pocan E product range can also be used with the significantly higher rated voltages that are required for rapid charging of electric vehicles, for example.”
CLICK ON THE LINKS FOR MORE INFORMATION: �
www.solvay.com �
www.ascendmaterials.com �
https://lanxess.com �
www.radicigroup.com �
www.basf.com �
www.dsm.com �
www.domochemicals.com �
www.covestro.com �
www.sabic.com �
www.dupont.com/mobility �
https://x2f.com
www.injectionworld.com
IMAGE: X2F/COVESTRO
IMAGE: SABIC
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