𝐍𝐞𝐰 𝐗𝐲𝐭𝐫𝐨𝐧™ 𝐏𝐏𝐒-𝐜𝐨𝐦𝐩𝐨𝐮𝐧𝐝 𝐛𝐨𝐨𝐬𝐭𝐬 𝐭𝐡𝐞𝐫𝐦𝐚𝐥 𝐬𝐡𝐨𝐜𝐤 𝐫𝐞𝐬𝐢𝐬𝐭𝐚𝐧𝐜𝐞 𝐨𝐟 𝐞𝐥𝐞𝐜𝐭𝐫𝐢𝐜 𝐯𝐞𝐡𝐢𝐜𝐥𝐞 𝐛𝐮𝐬𝐛𝐚𝐫𝐬 𝐛𝐲 𝐦𝐨𝐫𝐞 𝐭𝐡𝐚𝐧 𝟕𝟎%

Envalior, a leading global manufacturer of sustainable and high-performance engineering materials, has developed #XytronTMM5080ET, a new PPS (#PolyphenyleneSulfide (PPS) for overmolding and functionalizing busbars for #electricvehicles (EVs). The impact-modified compound is primarily designed for busbars that must withstand temperatures above 150°C while also being highly resistant to stress cracking during thermal shock. The material is a solution to rising temperatures in EV powertrains, driven by higher operating voltages, stronger currents & more compact assembly designs. This also increases the requirements for the thermal shock resistance of overmolded busbars, such as those used in #powercontrolunits (PCU) or electric drive axles of EVs.

Thermal expansion closer to copper improves resistance to stress cracking

In EVs, busbars must safely conduct electricity between the high-voltage battery, control unit, drive, and charging unit. They are made of copper and overmolded with plastic to provide electrical insulation from the surrounding environment. The challenge with such #overmolded components is that the thermal expansion of copper and plastic usually differs significantly, favoring the formation of #stresscracks in the plastic during abrupt and frequent temperature changes. The strength of the new compound is that, unlike comparable materials, its thermal expansion is closer to that of copper, even perpendicular to the melt flow direction and #glassfiber orientation in the part, and this stability is maintained even at high temperatures.

"Tests conducted at #Envalior have shown that our new compound exhibits over 70% higher stress crack resistance in thermal shock tests at temperatures between -50°C and 180°C compared to similar PPS compounds. This is supported by the fact that the #weldlines in the component, which are created by converging melt fronts are around 17% stronger than in comparable materials.

The material's high thermal shock stability is impressive given that PPS already exhibits the best stress crack resistance compared to other plastics used for #overmoldingbusbars.

V-0 rating in UL 94 test, dimensionally stable and impact resistant

XytronTM M5080ET offers high #flameresistance, as required for plastic applications in batteries and electric drive trains to protect vehicle occupants in the event of a fire. The material achieves the V-0 classification in the UL 94 test conducted by Underwriters Laboratories Inc., using a test specimen thickness of two millimeters. The compound also exhibits high volume resistivity and high dielectric strength before and after aging, even at high temperatures. In addition, its high creep resistance and low water absorption result in dimensionally stable components.

source : Envalior