Thermally Conductive Nylon 6 for Electric Sports Car Components | Plastics Technology

Cooling element of an electric sports car charge controller made of Durethan BTC965FM30 nylon 6 from LANXESS
Thermally conductive plastics show great potential in the thermal management of electric vehicle charging systems.A recent example is an all-electric vehicle charge controller for a sports car manufacturer in southern Germany.The controller contains a cooling element made of LANXESS’s thermally and electrically insulating nylon 6 Durethan BTC965FM30 to dissipate the heat generated in the controller plug contacts when charging the battery.In addition to preventing the charge controller from overheating, the material of construction also meets stringent requirements for flame retardant properties, tracking resistance and design, according to Bernhard Helbich, Technical Key Account Manager.
The manufacturer of the entire charging system for the sports car is Leopold Kostal GmbH & Co. KG of Luedenscheid, a global system supplier for automotive, industrial and solar electrical and electrical contact systems.The charge controller converts the three-phase or alternating current fed from the charging station into direct current and controls the charging process.During the process, for example, they limit charging voltage and current to prevent overcharging the battery.Up to 48 amps of current flow through the plug contacts in the sports car’s charge controller, creating a lot of heat during charging.”Our nylon is filled with special mineral thermally conductive particles that efficiently conduct heat away from the source,” Helbich said.These particles give the compound a high thermal conductivity of 2.5 W/m∙K in the direction of melt flow (in-plane) and 1.3 W/m∙K perpendicular to the direction of melt flow (through the plane).
Halogen-free flame retardant nylon 6 material ensures that the cooling element is highly fire resistant.On request, it passes the UL 94 flammability test by the US testing agency Underwriters Laboratories Inc. with the best classification V-0 (0.75 mm).Its high resistance to tracking also contributes to increased safety.This is evidenced by its CTI A value of 600 V (Comparative Tracking Index, IEC 60112).Despite the high thermally conductive filler content (68% by weight), nylon 6 has good flow properties.This thermally conductive thermoplastic also has potential for use in electric vehicle battery components such as plugs, heat sinks, heat exchangers and mounting plates for power electronics.”
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Post time: Jul-14-2022