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LANXESS’ New PBT/ASA Blend with Extremely Low Warpage for Vehicle Battery Systems

Published on 2017-07-14. Author : SpecialChem

PBT/ASA Blend for Battery Components
PBT/ASA Blend for Battery Components
LANXESS in collaboration with HELLA KGaA Hueck & Co. has developed a new compound called Pocan AF4130.

Pocan AF4130 - Housing Material for Battery Systems

  • It serves as a housing material for a battery management unit (BMU) and two cell monitoring units (CMU). 
  • It is a blend of polybutylene terephthalate (PBT) and acrylic ester-styrene-acrylonitrile (ASA).
  • It contains 30% by weight glass fibers- and a halogen-based flame retardance package. 

Marc Marbach, head of Sales Segments E&E in the LANXESS High Performance Materials (HPM) business unit, said:
“The particular advantages of the material are its extremely low warpage and shrinkage, combined with its high flame retardance. We see great potential for application in precision components for vehicle battery systems.”

BMU and CMUs for Vehicles

  • HELLA fabricates the BMU and CMUs for a German manufacturer of battery systems for motor vehicles. 
  • The very flat devices currently are used in the lithium-ion battery system of a German compact car.

Low Tolerances

Housing structures of BMU & CMUs are little different.
  • They have large, flat surfaces as well as complex geometries inside and also along the edges. 
  • They can be cost-effectively injection molded as single components due to their innovative design.
  • The contact pins for the connectors must not bend when the housings are mounted on the printed circuit boards. 
  • The tolerances for the spacing between the connector mounts and the cut-outs for the pins are extremely close. 

Marc Marbach explained:
“This is precisely where the outstanding dimensional stability of our blend Pocan AF4130 pays off.”

UL 94 5VA- and UL f1-listed

  • As per the application requirement, Pocan AF4130 achieves best classification of V-0 (0.75 millimeters) in UL 94 fire testing by the U.S. testing organization Underwriters Laboratories Inc. 
  • It is further listed on the UL Yellow Card with a good classification of UL 94 5VA (1.5 millimeters). 
  • The material is destined for the injection molding of flame-retardant housing components. 
  • It has also been given a UL f1 listing for use in outdoor applications involving exposure to UV light and water. 

Marc Marbach said:
“Our compound thus has a good chance of also being used for electrical components such as photovoltaic plugs and sockets.”

Pocan AF4130 Compound

Low Volatile and Condensable Emissions

Surfaces made of this thermoplastic have very low-emission. This is demonstrated by thermal desorption analyses conducted by LANXESS in accordance with VDA 278 (German Association of the Automotive Industry).

Marc Marbach said:
“It is therefore also suitable for many motor vehicle applications requiring very low volatile and condensable emissions, such as components for the automotive interior.”

Good Resistance to Common Battery Electrolytes

  • The blend is highly resistant to typical media used in motor vehicles, such as fuels, oils, cleansers and car care products. 
  • This has been proved in extensive media storage tests conducted by LANXESS for HELLA. The test are conducted in accordance with the supply specification LV 124 used by many automotive manufacturers. 
  • It also displays good resistance to an electrolyte which is widely used in lithium-ion batteries. The corresponding test was additionally conducted under load in compliance with DIN EN 22088-3. 

Marc Marbach explained:
“No cracks were evident in the samples even after 1,000 hours of exposure.”

Comprehensive HiAnt Services

LANXESS provided HELLA with extensive support in developing the housing components. These services are part of its HiAnt customer service package. For example:
  • HPM delivered suggestions for optimal component design. 
  • HPM provided all the characteristic material data required for the computer-aided design of the housing parts to meet expected loads for mold flow analyses and supported the initial injection molding trials. 
  • LANXESS further determined the blend’s halogenide content for HELLA by means of ion chromatography and conducted odor testing to VDA 270. 

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