Engineering plastics for New Mobility

QUALITY CHANGES.

Engineering plastics for New Mobility

The automotive industry is about to change significantly driven by numerous factors:

Environmental considerations Alternative electric powertrains Advancing digitalization and connectivity Trends towards car sharing and autonomous driving

These developments, which create new requirements for engineering thermoplastics in the automotive industry, ask for a whole range of new properties. Although some specifications for plastic components in vehicles and charging infrastruc-ture are still under discussion, the first plastic parts which meet these demanding requirements are now ready for mass production.

At LANXESS, we see new, environmentally friendly forms of mobility as a future-oriented growth segment for our Durethan® polyamide (PA 6 and PA 66) and Pocan® poly-butylene terephthalate (PBT) compounds as well as our Tepex® thermoplastic composites. This is based on our many years of experience and development expertise pertain-ing to plastic components for the automotive and electrical and electronic (E&E) industries. Our strong knowledge and innovative mindset drives our ability to support the leading-edge solutions when it comes to future mobility – or as we call it – New Mobility.

For further information visit our website.

NEW MOBILITY AS A DRIVER FOR INNOVATIVE SOLUTIONS

3LANXESS Engineering plastics for New Mobility

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COMPLEX COMBINATIONS OF REQUIREMENTS IN THE FIELD OF NEW MOBILITY

Due to the electrification of powertrains and the trend towards autonomous driving, new components like high-voltage (HV) batteries, inverters and collision avoidance sensors are integrated into the vehicle. This leads to com-pletely new combinations of requirements for thermoplastics materials, for example:

Flame retardance Electrical properties Thermal conductivity Orange color for HV applications Electromagnetic shielding Prevention of electrochemical corrosion

We will describe these characteristics in more detail on the following pages.

Well-known automotive design strategies such as lightweight design are still of great importance to increase the range of electric vehicles (EV). In comparison to metals such as steel or aluminum, plastics offer many advantages in addition to weight reduction:

Virtually unlimited freedom in color/design High level of integration possible Optimal use of available assembly space Versatility regarding processing Cost-effective mass production

We have identified several focus systems used in hybrid and battery electric vehicles which benefit from our high per-formance materials Durethan®, Pocan® and Tepex®:

1. Battery system2. Charging system (inside EV)3. Inverter4. DC/DC converter & electronic control unit (ECU)5. Auxiliary equipment6. E-Engine7. Connectors

Further applications for engineering plastics can be found in the field of charging infrastructure and autonomous driving. The first applications, such as wallboxes and charging plugs, are already in mass production with our materials.

Positioning of LANXESS focus systems Focus systems

1. Battery systems

Housing, cell-module, battery electrics,

cooling systems, mounting systems

2. Charging system (inside EV)

On-board charger, inductive charger,

charging socket, power distribution

3. Inverter

Power electronic

4. DC/DC converter & ECU

5. Auxiliary equipment

Air compressor, cooling pump,

PTC heater

6. E-Engine

Rotor, stator, housing, sensors

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Potential for PA and PBT

high

highmed

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Pictures: A2Mac1, LANXESS

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4 LANXESS Engineering plastics for New Mobility 5LANXESS Engineering plastics for New Mobility

FLAME RETARDANTSAN OVERVIEW

Plastics are generally flammable. Due to the growing need for electrified applications in the automotive industry, the im-portance of flame retardant materials is constantly increas-ing. Therefore specific additives must be added in order to offer materials with the highest degree of electrical and fire safety.

By means of flame retardants (FR), the flammability of materi-als and the speed of flame propagation is influenced. Coming from a long history of developments in the E&E industry, we can offer a wide range of polyamides and polyesters which fulfill the specific requirements and tests related to flame re-tardant materials (e.g. UL 94 V-0).

Most FR systems are based on chemical substances that contain elements such as bromine, phosphorous or nitrogen, and are compounded with the polymer matrix. Their modes of action, advantages and disadvantages vary. The most important systems and modes of action for PA 6, PA 66 and PBT are described below and visualized in the illustration on page 7.

Halogenated flame retardants (Radical recombination)Bromine is present in these flame retardants as organic halogen compounds. Halogen radicals are produced dur-ing combustion and they intercept the energy-rich hydrogen and hydroxyl radicals in the flame, extracting its energy (1).

Inorganic flame retardants (Fire inhibiting gases)Inorganic flame retardants such as magnesium hydroxide split off water when consuming energy. As a result the matrix cools and the combustion gases are diluted with water (3).

Phosphorous-based flame retardants (Surface passivation) Phosphorous is compounded into the plastic either as in-organic red phosphorous or as an organic phosphorous substance. In a fire, phosphorous substances produce phos-phorous oxides, which remove water from the substrate, thus charring the polymer matrix (4). The carbon char layer separates the flame from the polymer, taking away its “fuel source”. Organic phosphorous substances are often used in combination with nitrogen-based substances.

Red phosphorous can produce corrosive gases and its inher-ent color limits its use to dark colored applications. Organic phosphorous substances are significantly less corrosive and do not have coloring restrictions. As a reason, we only use organic phosphorous substances instead of red phospho-rous for our materials.

Nitrogen-based flame retardants (Intumescence, Fire inhibiting gases, Matrix depoly-merization)Nitrogen-based flame retardants produce their effect by vari-ous modes of action. Initially, they decompose when subject-ed to heat which draws off energy from the flame area (3). In addition, gases are produced that allow foaming of the matrix which prevent oxygen and heat going into the poly-mer (2). Furthermore a matrix depolymerization can occur so that the matrix draws away from the heat source (5). Nitro-gen-based flame retardants are less effective in reinforced polymers, which is why they are often combined with phos-phorous based systems.

FLAME RETARDANTS IN PLASTICSMODE OF ACTION

The illustration shows in summary form, how and where flame retardants act.

1 Radical recombination Halogenated FR additives

2 Intumescence Foam produced by intumescence system (blowing agent)

3 Fire inhibiting gases Decomposition of water from minerals as Mg(OH)2

Decomposition of N2/NH3 from melamine cyanurate

4 Surface passivation Char formation by phosphonic acid or red phosphorous

5 Matrix depolymerisation Depolymeration induced by FR system

Oxygen

Char

Flammable gases

Polymer

Thermal back coupling

Heat Smoke Combustion products

2

1

3

4

5

7LANXESS Engineering plastics for New Mobility6 LANXESS Engineering plastics for New Mobility

FLAME RETARDANTS IN PLASTICS GRADES AND APPLICATIONS FOR NEW MOBILITY

The type of flame retardant system used, depends on the ap-plication and its specific requirements. The table shown be-low gives an overview of the advantages and disadvantages of halogenated vs. halogen-free flame retardants.

Innovative flame retardant compoundsWe provide a wide portfolio covering compounds containing halogenated as well as halogen-free flame retardants. The development of halogen-free flame retardant compounds is an especially strong focus for applications in New Mobility. Here, we have developed innovative grades in the area of PA 6 and PBT resins. Highly reinforced flame retardant mate-rials such as Durethan® BKV45FN04 (PA 6 GF45, halogen-free FR) are ideal for metal replacement in battery systems, wallbox housings or for HV connectors with special orange coloration. Its strengths are:

Outstanding flame protection properties (e.g. UL 94 V-0 at 0.4 mm)

Excellent stiffness and strength in combination with good flowability

High tracking resistance (CTI A 600 V)

Beside good chemical and heat resistance these products exhibit:

Excellent flame retardancy (e.g. UL 94 V-0 at 0.4 mm) Low warpage and shrinkage Option for high color stability in outdoor applications

These are just two examples of our broad portfolio of flame retardant plastics. For a complete overview please refer to our website.

Another innovative material is Pocan® AF4110 (PBT+ASA GF12, halogenated FR). Like its siblings with 20 and 30 per-cent glass fiber content, this material is suitable for applica-tions such as battery cell housings and plug connectors.

ELECTRICAL PROPERTIES GRADES AND APPLICATIONS FOR NEW MOBILITY

In addition to flame retardant requirements, electrical prop-erties are gaining more and more importance when talking about applications for New Mobility. One of the most common requirements is testing according to IEC 60112 or UL 746A, which specifies the CTI. The test is done by al-lowing successive drops of a standard electrolyte solution to fall on a polymer specimen in the area between two live electrodes (see graphic). The CTI A is the highest voltage at which no failure (i.e. tracking) occurs after 50 drops have fallen on each of the five specimens. Application standards, e.g. DIN EN 60664, translate the measured CTI value into design requirements for clearance and creepage distances between two electrically live parts.

Further important electrical requirements are high dielectric strength or specific volume and surface resistivity.

Materials with high tracking resistanceGrades with halogen-free flame retardants play a significant role when it comes to electrical behavior. These plastics offer excellent electrical insulation properties combined with high stiffness and strength, heat and chemical resistance as well as abrasion resistance.

One example is Pocan® BFN4231 (PBT GF25, halogen-free FR), which is particularly suitable for electrical equipment with demanding requirements regarding dimensional stabil-ity such as sensors or plug connectors. It is also available with 13 and 20 percent glass fibers. All of these reinforced PBT grades show:

Excellent flame retardant properties (e.g. UL 94 V-0 at 0.4 mm)

Outstanding electrical insulation (e.g. up to CTI A 600 V or PLC 0)

Long-term heat stability (RTIs ≥ 140 °C)

Low tendency for electrochemical corrosion with metals

For electrical applications such as HV connectors as well as large and complex housings within the battery, we have several products, including Durethan® BKV25FN04 (PA 6 GF25, halogen-free FR) and BKV30FN04 (PA 6 GF30, halogen-free FR). These products are characterized by:

High flame retardant properties (e.g. UL 94 V-0 at 0.75 mm)

Excellent electrical performance (e.g. up to CTI A 600 V or PLC 0)

Good UV resistance Wide processing range compared to former

halogen-free FR-systems

Comparative Tracking Index (CTI)

CTI rangeTracking Index (TI) in V

PLC assigned

600 ≤ TI 0

400 ≤ TI < 600 1

250 ≤ TI < 400 2

175 ≤ TI < 250 3

100 ≤ TI < 175 4

0 ≤ TI < 100 5

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FR-system Advantages Disadvantages

Halogenated High thermal stability - easy processing Low influence on mechanical properties High performance at the Glow Wire Ignition Temperature (GWIT) test for PA grades

Negative reputation in public Higher density

Halogen-free Excellent electrical properties (e.g. Comparative Tracking Index (CTI))

Low discoloration under UV and heat Better contrast for laser marketing ‘white on black

,

Negative influence on mechanical properties Smaller processing window

Test solution

ElectrodeElectrode

Cu Steel30

- 4

0 m

m

Tracking paths

Specimen

Cell carrier made of Pocan AF4110 for E-Bikes and E-Scooters

PLC: Performance Level Category


INCREASING DEMAND FOR THERMALLY CONDUCTIVE PLASTICS

The increasing number of electronic components in cars and the higher energy density of electric motors, batteries and electronics leads to new requirements for efficient heat dis-sipation while maintaining electrical insulation.

With their high thermal conductivity metals like steel or alu-minum would seem to be the first choice for thermal man-agement. But due to the miniaturization of E&E components and the trend towards cheaper and less complex thermal management systems, thermally conductive plastics are becoming more and more interesting. Compared to metals, they offer significant advantages in terms of weight reduc-tion and functional integration. In general, the more complex the component geometry, the greater the potential for ther-mally conductive plastics.

For most applications, a thermal conductivity of λ = 1 - 2 W/m.K is sufficient when the component geometry can be adapted to optimize heat convection.

Thermally conductive and electrically insulating materialsWith our materials in the Durethan® BTC range, we offer thermally conductive and electrically insulating polyamide compounds. These highly mineral-filled grades are replacing die-cast metals or standard plastic materials in parts such as electronics housings.

Specific grades in this range are Durethan® BTC65H3.0EF (PA 6 MD65) and BTC75H3.0EF (PA 6 MD75). These materials can be used for complex precision components with tight dimensional tolerances such as passive cooling elements, charging system components or modular flanges for Heating, Ventilation and Air Conditioning (HVAC) applica-tions. With their thermal conductivity up to 1.7 W/m.K, the Durethan® BTC grades help to protect electronical devices from thermal overload. In addition, they exhibit

low warpage and nearly isotropic shrinkage, good long-term heat resistance and high stiffness and strength.

The halide-free heat stabilization in these grades prevents cor-rosion of the copper contacts, which are often integrated into such parts. Despite their enhanced thermal conductivity, the materials still exhibit good flowability, which enables injection molding at reduced pressure. This ensures that there is no deformation of the contacts when the material is being over-molded.

NEW THERMALLY CONDUCTIVE GRADES APPLICATIONS FOR NEW MOBILITY

Thermally conductive materials with improved flowabilityTo attain the required increase in thermal conductivity, high filler contents are needed. With this in mind, we are always anxious to develop grades which successfully meet high re-quirements for conductivity, flowability and processability. A result of these efforts are the newly developed thermally con-ductive Durethan® grades TP430-003 “BTC77ZH3.0EF” (PA 6 MD77) and TP430-004 “BTC67ZH3.0EF” (PA 6 MD67) with improved flowability, especially at higher shear rates.

Improved flowability at 290 °C

These new materials are characterized by an outstand-ing toughness despite the high filler content. The strain at break and the impact strength are especially impressive.

In addition to that, the materials also offer

almost isotropic thermal conductivity in in-plane and through-plane direction and

low warpage and isotropic shrinkage.

At LANXESS, we are continuously expanding our range of polyamide compounds for components used in the thermal management of electrical devices. Another innovative mem-ber of the BTC product family is Durethan® BTC965FM30 (PA 6 MD68 FR). The special feature behind this PA 6 is its outstanding thermal conductivity combined with excellent fla-me retardancy (halogen-free) and reflectivity.

With a thermal conductivity of 1.3 W/m.K in the through-plane direction and 2.5 W/m.K in the in-plane direction, it achieves almost ten times higher values than a standard PA 6 GF30.

Outstanding flame retardancy and electrical propertiesThe main characteristics of Durethan® BTC965FM30 are excellent flame retardancy, which is attributable to a halogen-free flame retardant package and good electrical properties. Due to this, electrical assemblies can be positioned closer to each other without resulting in short circuits or device defects caused by leakage current. The material also

has a UL 94 V-0 classification at 0.75 mm, achieves excellent values in glow-wire tests and exhibits a high tracking resistance (CTI A 600 V).

Despite the high mineral content necessary to achieve good thermal conductivity, the density of 1.7 g/cm³ is compara-tively low for this PA 6 compound, meaning it can support cost-efficient, lightweight component solutions.

Durethan TP430-003 Durethan TP430-004 Durethan BTC75H3.0EF Durethan BTC65H.0EF

Shear rate in 1/s

1,000

100

101 10 100 1,000 10,000 100,000

Vis

cosi

ty in

Pas

Grade Type Thermal conductivity (in- / through-plane) in W/m•K

Strain at break (d.a.m. / cond.)in %

Remark

Durethan BKV30H3.0 PA 6 GF30 0.2 / 0.2 3.8 / 6.0

Durethan BTC65H3.0EF PA 6 MD65 1.3 / 1.0 3.0 / 5.0 Good processability

Durethan BTC75H3.0EF PA 6 MD75 1.7 / 1.4 1.8 / 2.2 High modulus

Durethan BTC965FM30 PA 6 MD68 FR 2.5 / 1.3 0.7 / 1.2 Halogen-free, high reflectivity

Durethan TP430-003 PA 6 MD77 1.8 / 1.7 3.2 / 5.1 High modulus, improved flowability

Durethan TP430-004 PA 6 MD67 1.1 / 1.0 3.2 / 13 Enhanced toughness, improved flowability

Thermally conductive modular flange for HVAC system made of Durethan BTC75H3.0EF


ORANGE COLORFOR HIGH VOLTAGE APPLICATIONS

BROAD PORTFOLIO OF ORANGE DURETHAN AND POCAN MATERIALS

Color stability during lifetimeAdditionally to an accurate color tone, the color stability dur-ing lifetime becomes more and more important. This require-ment is important to ensure a clear identification of HV com-ponents also after years. With regard to these requirements, the color stabilization becomes more and more important.

The illustration below shows the color stability under heat of Durethan® BKV30FN04 200849 with improved color stabil-ity compared to a reference without improved color stability. The orange colored LANXESS materials exhibit no discolor-ation or bleeding under typical processing requirements. In addition, they show a sufficient color stability at 130 °C over a period of 1,000 hours respectively 42 days (d).

If further improved color stability is required, Durethan® and Pocan® grades with enhanced tailor-made stabilizer systems are available.

Further requirementsFurther essential characteristics for orange colored HV applications can be determined by the selection of the specific PA 6, PA 66 or PBT compound. For demanding applications in the field of New Mobility and E&E, we have developed ma-terials with various characteristics:

Flame retardancy (UL 94 V-0) CTI A 600 V or PLC 0 High dielectric strength Halide-free heat stabilization for the prevention

of electrochemical corrosion Laser markability in white and black Excellent processability

UL Yellow Cards with all color listings The flame retardant compounds especially developed for HV applications are halogen-free and free from red phosphorous. Self-coloring of natural grades by using masterbatches is pos-sible, but then the UL Yellow Card for the natural grade is not valid after self-coloring. A UL Yellow Card will be provided for each orange grade listed in table below.

HV connectors in orange

Grade Type UL 94 classification CTI A 600 V / PLC 0 Remark

Durethan BG30XH3.0 PA 6 (GB+GF)30 HB Low tendency to warp

Durethan BKV20FN01 PA 6 GF18 FR V-0 at 0.75 mm X Halogen-free

Durethan BKV30FN04 PA 6 GF30 FR V-0 at 0.75 mm X Halogen-free

Durethan BKV45FN04 PA 6 GF45 FR V-0 at 0.4 mm X Halogen-free, high modulus

Pocan BF4232HR PBT GF30 V-0 at 0.4 mm Hydrolysis stabilized

Orange color grades

Illustration of orange colors for Durethan and Pocan: RAL 2003 (LANXESS color code: 200849) and RAL 2010 (LANXESS color code: 201194)

RAL 2003 RAL 2010

Durethan BKV30FN04 200849 with improved color stability

Reference without improved color stability

One of the key factors for New Mobility is the electrified powertrain which contains HV components together with an HV battery and charging system, to enable acceptable charging times. In order to guarantee safe handling of the components in the main charging path of the battery, orange coloring is prescribed as a safety and distinguishing feature. The HV parts must remain clearly identifiable for years which is important for rescue teams in the event of an accident as well as for maintenance work.

Multiple solutions for orange applicationsMarket requirements for orange colored components are currently increasing. RAL 2010 is still accepted by the market, but the demand for a brilliant orange color respec-tively RAL 2003 is significantly increasing. Therefore, we offer several orange color solutions for HV components. Our Durethan® and Pocan® grades are available in the following colors:

Brilliant orange (RAL 2003, LANXESS color code 200849)

Standard orange (RAL 2010, LANXESS color code 201194)

On demand in further orange colors Natural color for self-coloring

(LANXESS color code 000000)


INCREASING DEMAND FOR ELECTROMAGNETIC SHIELDING

MATERIAL SOLUTIONS FOR ELECTROMAGNETIC SHIELDING

A significant effect of the change in technology is the sub-stantial increase of the number of electronic components in the vehicle, mainly driven by the powertrain electrification and autonomous driving. Due to increasing miniaturization, electronic components move closer together, enabling un-desired interaction in the form of electromagnetic interfer-ence. It is therefore a key factor for New Mobility to ensure electromagnetic compatibility of sensitive electronic com-ponents which often are responsible for safety-relevant sys-tems in the vehicle. In this context, special attention must be paid to electromagnetic shielding (EMS) of the power electronics, the electric engine and the HV battery system including the on-board charger.

Due to their very high intrinsic electrical conductivity, met-als are suitable materials for parts with a high demand for shielding from electrical fields and electromagnetic waves, such as housings or covers. In addition, they are character-ized by high stiffness, strength, temperature stability and thermal conductivity. Tailor-made polyamide or polyester compounds can provide almost the same properties. In ad-dition to that the use of these materials offers further great advantages such as:

Weight reduction Virtually unlimited freedom in color/design Simple integration of additional functionalities Inexpensive and fast production by injection molding

We have developed innovative materials for shielding of elec-tric, magnetic and electromagnetic fields which can be used for the production of plastic parts with high EMS properties. Our product range includes:

Electrically conductive polyamide compounds Durethan® and Pocan® materials suitable for various coat-

ing technologies Continuous fiber reinforced thermoplastics, equipped

with a shielding layer on the surface

Electrically conductive polyamide compoundsIn the field of electrically conductive polyamides we offer Durethan® BCF30H2.0EF, a PA 6 CF30, that can be used for the production of sensor housings in addition to other ap-plications. It exhibits good shielding performance in MHz to GHz frequency range. Further strengths are:

High stiffness and strength Good flow properties Good chemical and heat resistance

Additional effective ways to produce shielding in plastic parts are:

Application of a coating with shielding properties, e.g. by thermal spray, galvanization, physical vapor deposition (PVD) or conductive paint application

Insertion of a shielding film, non-woven or mesh during injection molding (In-Mold-Decoration (IMD) process)

A major advantage of both processes is that many Durethan® and Pocan® materials can be used for the injection molding component. In this way additional characteristics such as flame retardancy or thermal conductivity can be added to the part.

High performance fiber composites with an EMS layer Another innovative approach is our continuous fiber reinforced thermoplastic material, Tepex®, which can be added during the production process on one or both sides to act as shielding surface layers. After heating, the Tepex® containing EMS layer can be formed and overmolded. It is well suited for the produc-tion of covers for on-board chargers, power electronics and for battery cases. Among other characteristics such parts exhibit

very good shielding properties over a broad frequency range, excellent crash protection and very high stiffness and strength.

Components of an electrified vehicle with demand for electromagnetic shielding

Prototypes of covers from Tepex with EMS layer

Shielding effectiveness of Durethan and Tepex with EMS layer compared to Aluminum

Sh

ield

ing

eff

ecti

ven

ess

in d

B

Frequency in MHz1,00010010

Durethan BCF30H2.0EF Tepex 102-RG600(4)/47% with EMS layerAIMg4.5Mn70

60

50

40

30

20

10

0


ELECTROCHEMICAL CORROSIONOF METAL INSERTS IN PLASTIC PARTS

New Mobility applications with high demands for functional safety and flame retardancy such as connectors and cable brackets are becoming more and more relevant. These parts have to withstand various environmental influences combined with high voltages and currents. Typically for such parts, a combination of metal and plastic is used. Therefore, one of the main challenges is the prevention of electrochemi-cal corrosion which can lead to short circuits, functional fail-ure or leakage.

High humidity, highly aggressive media such as electrolyte solutions, as well as high temperatures and high voltages of the ambient electrical field are the main environmental fac-tors which can cause corrosive reactions and could lead to part failure. In addition, the composition of the plastic can have an influence on the mechanisms that drive the cor-rosive reactions. Particularly noteworthy in this respect are heat stabilizers containing halides, flame retardants contain-ing red phosphorus as well as some colorants.

Typical failure mechanisms of electrochemical corrosion are:

Direct corrosion from gas phase

Heat stabilizations for Durethan grades

Gap and contact corrosion

METAL

Outgassing of vapor

Corrosivereactions

PLASTIC, E.G. HOUSING

Direct corrosion from gas phase

METAL

Corrosivereactions PLASTIC,

E.G. HOUSING

Gap and contact corrosion

METAL

METAL

Deposits and dendrites cause short circuits

PLASTIC

Deposits and dendrites causing short circuits

ELECTRICALLY NEUTRAL HEAT STABILIZATIONTO AVOID ELECTRO- CHEMICAL CORROSION

In order to ensure function and quality of electrical parts over their lifetime we provide materials with electrically neutral heat stabilization such as our H3.0 and XTS3 grades. These stabilizations were developed for applications which require very low halide content such as connectors or housings, es-pecially in HV applications. Over several years of experience in the field, typical corrosion phenomena were avoided by these copper- and halide-free stabilizers.

Every grade of our flame-retardant Durethan® and Pocan® material portfolio is stabilized using a halide-free heat stabili-zer and is free of red phosphorous.

Low halide contentAs a way to achieve the lowest possible halide content in order to avoid contamination with halides and the resulting corrosive reactions, we provide selected materials that use the DUSLHC (low halide content) production process. This special production process avoids the contamination of the compound with halides. With this respective measure, we can produce grades that meet specified halide content limits. From experience, we recommend the DUSLHC only for ex-tremely critical parts in terms of electrochemical corrosion. Most applications can safely be produced without the DUS-LHC process by relying on our H3.0 and XTS3 organic heat stabilizers.

One example of such a material is our Durethan®

BKV30H3.0EF DUSLHC (PA 6 GF30). Due to its good elec-trical properties (CTI A 600 V) in combination with excellent flowability it is well suited for thin wall applications e. g. in the battery such as cell spacer or end plates.

Cell spacer from Durethan BKV30H3.0EF DUSLHC

Copper-based Copper- and halide-free

240 –

220 –

200 –

180 –

160 –

140 –

120 –

100 –

80 –

XTS2

XTS1 XTS3

H2.0

H3.0

Not stabilized

°C


LANXESS PORTFOLIO FOR HIGH VOLTAGE BATTERIES

High Voltage Connectors

Halogen- and red phosphorous-free flame retardant: UL 94 V-0 at 0.4 mm

CTI A 600 V

High mechanical performance (tensile modulus: 15,900 MPa)

Various orange color

Durethan BKV30FN04

Side Plate

Plastic/Metal Hybrid part

Halogen- and red phosphorous-free flame retardant: UL 94 V-0 at 0.75 mm

CTI A 600 V

Good surface quality

Durethan BKV45FN04

Cooling Pipes

Water-glycol resistant up to 100 °C

Good processing capability in gas-injection-technology

Good surface quality

Durethan BKV30GDurethan BM40XEF

Battery Housing and Cover

High impact energy absorption

Flame-retardancy

Maximum weight reduction

Tepex dynalite

Cable Brackets

Red phosphorous-free flame retardant: UL 94 V-0 at 0.75 mm

Chemical resistance according to LV124 (incl. electrolyte)

High toughness and strain

Excellent processability and surface quality

Durethan BKV20FN01

Battery Management System Housing

Halogen-containing flame retardant: UL 94 V-0 at 0.75 mm

Low warpage

Chemical resistance according to LV124 (incl. electrolyte)

Pocan AF4130

Cell Spacer

Copper- and halide-free heat stabilization

CTI A 600 V

Good mechanical performance

Improved Flowability

Durethan BKV30H3.0EF DUSLHC

End Plate

High mechanical performance (tensile modulus: 19,400 MPa)

Improved flowability

Copper- and halide-free heat stabilization

Durethan BKV60EF DUS097

18 LANXESS Engineering plastics for New Mobility

We offer a broad portfolio of engineering plastics for New Mobility applications. The HV battery is a fundamental com-ponent in electric vehicles that requires materials with out-

standing properties. The following drawings provide an over-view of our material solutions for different applications within the HV battery, including the cell module.


LIGHTWEIGHT IS ESSENTIAL FOR NEW MOBILITY

One approach to resource conservation and climate protection is the reduction of vehicle weight. Specifically for New Mobil-ity applications, reduced vehicle weight allows higher driving ranges as well as increased driving performance in hybrid and battery electric vehicles. Thanks to many years of experience we are a reliable partner for lightweight solutions. With our range of high performance thermoplastic materials, namely Durethan®, Pocan® and Tepex®, we offer products and tech-nologies for automotive lightweight design which enable the replacement of metals with plastics.

High-modulus plasticsUsing high-modulus Durethan® grades with 60 percent glass fibers, we are able to provide precisely the right so-lution. Offering stiffness of up to 23,000 MPa and high strength of up to 250 MPa, these grades achieve values comparable to those of die-cast materials and are there-for well suited to the substitution of metals – especially for structural applications that are subject to high levels of stress. Substituting plastic for metal not only saves weight, but in many applications it also allows a significant num-ber of functions to be integrated into the individual part.

These high-modulus polyamides

are exceptionally stiff and strong, and have a damping effect on the structure,

have very good flow properties despite the high glass fiber content and

support wall thicknesses of one millimeter or less.

In addition to very good mechanical properties, our Durethan® BKV45FN04 (PA 6 GF45 FR) offers excellent flame retardancy and high tracking resistance, as mentioned on page 8. Potential applications regarding this combination of properties are battery housings, end plates in 48 V or HV batteries and charging plugs.

Plastic/Metal Hybrid TechnologyThe plastic/metal hybrid technology is an established meth-od for manufacturing lightweight structural components that systematically combines the advantages of metal and plas-tic. We have now extended the use of our hybrid technology to metallic hollow profiles with round or rectangular cross sections. Compared to sheet metal, hollow profiles show significantly higher dimensional stability as well as increased torsional strength and stiffness.

For more information about our lightweight solutions, follow this link:

TEPEX ALTERNATIVE TO METALS

Besides high-modulus plastics or plastic/metal hybrid so-lutions, a plastic/plastic hybrid solution is also possible. Tepex® high performance fiber composites offer high strength and stiffness at very low weight. At around 1.4-1.8 kg/dm³, its density is much lower than that of steel or even aluminum (7.8 and 2.7 kg/dm³, respectively). It can be stronger than metal, while the slightly lower stiffness can be compensated in many cases by using intelligent lightweight designs.

Our Tepex® materials consist of one or more layers of semi-finished textile products with continuous fibers embedded in a matrix of thermoplastics. Continuous fibers are mainly glass and/or carbon fibers in the form of fabrics, inlays or other semi-finished products. Matrix materials are thermo-plastics such as PA 6 and PA 66. Tepex® is fully impregnated and consolidated. Thus it is ideal for structural applications. All of the fibers are sheathed with plastic and the material does not contain any air pockets.

Tepex® is produced in a type of double belt press under de-fined conditions for heat, pressure and time. Special semi-fin-ished textile products are used to produce these fiber com-posite materials in order to optimize their design with regard to the required fiber orientation and to ensure efficient and reproducible component manufacturing.

Hybrid molding processTypically, Tepex® is combined with injection molding or com-pression molding. This opens up all of the benefits of traditio-nal hybrid technologies, such as

close bonding of various materials, ribbing designed according to loading requirements and functional integration by overmolding.

The process for manufacturing Tepex® components compri-ses the following steps:

Heating the composite blank above the melt temperature of the thermoplastic

Transporting the heated blank to the mold Incorporating and positioning the heated blank

in the mold Forming using appropriate mold technology If necessary, pressing or molding on a further

thermoplastic component Cooling and removing the finished part from the mold

Properties High-modulus plastics Die-cast metals

Density

Tensile Modulus

Resistance against deflection

Stress/Strain at break

Design freedom, potential for functional integration

Surface finish, finishing work

Processing and assemby costs

Color

Comparison of high-modulus plastics and die-cast metals regarding key properties

Cycle Time

Tem

pera

ture

BACK- INJECTION

Mold Temperature

Tepex Temperature

Tepex /plastic hybrid (hybrid molding)

HEATINGINSERTION FORMING BACK-INJECTION COOLING REMOVAL


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TEPEXAPPLICATIONS FOR NEW MOBILITY

The strengths of Tepex® can be summarized as follows:

Excellent mechanical properties High lightweight design potential thanks to low density Very short cycle times in component manufacturing Thermoplastic matrix enables overmolding and welding Excellent design flexibility Solvent-free Recyclable Low coefficient of thermal expansion Good dimensional stability Chemical and corrosion resistance

Tepex® is established for structural applications, such as front end upper beams, brake pedals, airbag housings, seat shells, door modules and infotainment brackets.

HIANTOUR KNOW-HOW SERVICING YOUR NEEDS

With HiAnt®, we support our customers at all stages of com-ponent engineering – from the initial idea and design to mold construction and the start of production. Our aim is to help you to reduce development costs and time-to-market. Ex-amples of selected services relevant for New Mobility applica-tions include:

Feasibility, weight, cost and risk analyses Application-specific recommendations for material selec-

tion and advice on plastic molded part designs with an eye to manufacturability

Simulating the production process and mold filling (Optimized injection point, minimization of warpage)

Simulating the mechanical behavior of components Standard- and specification-compliant performance in

important flame retardant tests Plastics-appropriate design of heat dissipating

components Standard- and specification-compliant component testing,

to determine long-term resistance to chemicals or heat

Carrier plate for electronic components made from Tepex

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Concept Development

Computer A

ided En

gin

eering

Mat

eria

l Dev

elop

men

t

Part Testing Processin

g

As shown before, we are developing solutions to modify Tepex® for electromagnetic applications. In doing so, differ-ent electromagnetic shielding systems are integrated into the production line. Combined with its outstanding mechani-cal performance, Tepex® is a promising material for battery housings with respect to crash performance and electromag-netic shielding. Other possible applications are housings for inverters and ECUs.

Another application area is a carrier plate for electronic com-ponents which was developed for a German sedan. The ben-efits compared to a conventional plastic or metal solutions are

less weight, a high degree of functional integration and fewer welding operations during part production.

For more information about our Tepex® materials, please follow the QR-code.


LANXESS Deutschland GmbHHigh Performance Materials50569 Cologne

new-mobility.lanxess.comdurethan.compocan.comtepex.comdurethan-pocan@lanxess.com

This information and our technical advice - whether verbal, in writing or by way of trials - are given in good faith but without warranty, and this also applies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to verify the information currently provided - especially that contained in our safety data and technical information sheets - and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility.

Trial Products (grade designations beginning with the code TP) are sales products at the developmental stage. For this reason, no assurances can be given as to type conformity, processability, long-term performance characteristics or other production or application parameters. No definitive statements can be made regarding the behavior of the product during processing or use. The purchaser/user uses the product entirely at his own risk. The marketing and continued supply of this material are not assured and may be discontinued at any time.

Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery.

Durethan®, Pocan®, Tepex® and HiAnt® are registered trademarks of the LANXESS groupOrder No.: LXS-HPM-074EN, Edition: 2019-09© LANXESS Deutschland GmbH 2019 | all rights reserved

Engineering plastics for New Mobility

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