Transcript 42 Volts - Distrupol

42 Volts - Plastic in
Automotive E & E Systems
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Use of Polymer in Cars
11.2% (142Kg) of total weight, (excluding tires).
5.80%
10.80%
51.10%
Body
31.90%
Interior
Drive
Source: BMW
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10.40%
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Chassis
E&E
Trends in Automotive Technology
• Yesteryears
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Trends in Automotive Technology
• Today
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Trends in Automotive Technology
• The future
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Trends in Automotive Technology
• Reduce exhaust emissions.
• Better fuel economy.
• Improved safety.
• Increase comfort and convenience.
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Trends in Automotive Technology
European Union Directive 2000/53/EC
“End of Life Vehicle”
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Trends in Automotive Technology
8 to 9 million tonnes of waste every
year.
• Design and Manufacture for reuse,
recycling and recovery.
• Reduction and control of Hazardous
substances.
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Idle-Stop Air Conditioning
• First justification for 42 Volts.
• Car makers are unanimous.
• Today’s batteries (14 Volts) cannot supply
the energy.
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Impact on some applications?
• Integrated Starter Alternator.
• Proliferation of Electric Motors and
Actuators.
• Electric Water Pumps/Systems.
• A completely new air conditioning system.
• More Solenoids, Sensors, etc.
• Higher requirements for Connectors,
Switches.
• Integrated Control Modules.
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Trends in Automotive Technology
All trends require more electrical power
(Battery from 2kW to 6kW and beyond ?)
Increase in power require more voltage
Hence 42 Volts
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Impact on Plastics?
Noticeable shift from:
• Thermosets to Thermoplastics.
• Amorphous to Crystalline polymers.
• Moderate to High temperature materials.
• Approx. 25% increase in volume of Plastics.
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Impact on Plastics?
• Higher temperature performance
Miniaturisation of components
Higher power and higher temperature
requirements
Increase in ambient temperatures
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Heat Deflection Temperature
Weight
Thermometer
Heating Solution
Test Bar
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Heat Deflection Temperature
Gives an indication on the Maximum short
term temperature a polymer can withstand
under load.
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Beware!
Crastin* S600F10 (Unreinforced PBT)
HDT @0.45MPa
HDT @1.8MPa
160 0C
60 0C
Crastin* SK605 (30% Glass Fibre PBT)
HDT @0.45MPa
HDT @1.8MPa
HDT @5.0MPa
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220 0C
205 0C
180 0C
Relative Temperature
Index
Gives an indication of the long term
temperature behaviour of a Plastic in respect to
their;
Electrical properties
Mechanical properties with impact
Mechanical properties without impact
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RTI
Temperature at which after 60,000 hours (7
years) the properties drops to 50% of it’s initial
value.
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RTI
Zenite* 7130 Black (30% Glass Fibre LCP), @1.5
mm wall section.
Electrical properties
Mechanical properties with impact
Mechanical properties without impact
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240 0C
210 0C
240 0C
Beware
HDT  RTI
Zytel* 101L (Nylon 6.6)
HDT @ 0.45MPa
RTI W/O Imp.
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2000C
850C
A Rough Guide
260
PEEK
Long Term (RTI ºC)
240
Zenite* LCP
220
200
Phenolic
180
Vespel* PI
Ryton* PPS
PEI
Xtel* PPS/PA
160
Zytel* HTN PPA
140
Rynite* PET
120
PA 4/6
Crastin* PBT
100
180
200
220
240
260
280
300
Short Term (HDT ºC)
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320
340
360
380
Impact on Plastics?
• Higher temperature performance
• Higher arc resistance
Fuses, switches, relays, connectors
(connection & disconnection under
load).
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Impact on Plastics?
• Higher temperature performance
• Higher arc resistance
High amperage arc resistance (HAI) - Simulates
an arc occurs between two electrodes, under low
voltage but a high current, e.g. the connector pins
of a plug.
Or
High voltage, low current, dry arc resistance Simulates a conductive path, subject to high
voltage between two electrodes, e.g. high voltage
conductors separated by a insulator.
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Impact on Plastics?
• Higher temperature performance
• Higher arc resistance
• Higher track resistance
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CTI
The relative resistance of a material to tracking
for voltage up to 600V, when the surface is
exposed under electric stress to water with the
addition of contaminants.
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Impact on Plastics?
•
•
•
•
Higher temperature performance
Higher arc resistance
Higher track resistance
Flame retardant resins
Wiring insulation, connectors
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UL94 Flammability
25.4mm
76.2mm
25.4mm
SPECIMEN
WIRE GAUZE
450
The HB rating is given if the burn rate, measured between the 2 marks,
does not exceed:
38,1 mm / min for 3,2 mm test bar thickness
63,5 mm / min for < 3,2 mm test bar thickness if the test bar stops burning
before reaching the 100 mm mark.
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UL94 Flammability
12,7
Classification:
127 mm
9.5 mm
305 mm
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UL
V-0
V-1
V-2
2x10 s
2x10 s
2x10s
Max burning time single
specimen
<10 s
<30 s
<30 s
Max burning time 5
specimens
<50 s
<250 s
<250s
No of flame applications
Significance:
Dripping ignition of cotton
no
no
yes
Afterglow
<30 s
<60 s
<60 s
Afterglow ignition of cotton
none
none
yes
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UL94 Flammability
5VA classification (bars & plaques)
Specimen
1. No flaming or glowing - 60 s after
last flame application.
2. No ignition of the cotton by
dripping particles.
200
3. No holes in plaques.
A one time re-testing of a set of test
specimens is allowed if only 1 test bar
fails.
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Impact on Plastics?
•
•
•
•
•
•
•
Higher temperature performance
Higher arc resistance
Higher track resistance
Flame retardant resins
Glow wire
EMI Shielding
Electrical/Heat conductivity
Electronic control modules, wireless sensors,
pump housings/impellers
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Impact on Plastics?
•
•
•
•
•
•
•
Higher temperature performance
Higher arc resistance
Higher track resistance
Flame retardant resins
Glow wire
EMI Shielding
Electrical/Heat conductivity
Higher frequency and/or higher power devices,
creates more EM radiation
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Surface and Volume resistivity
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Conductive Additives
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Semi-conductive polymers
• RTP ESD-C-1000; PBT
Surface resistivity <106 ohms/sq
Volume resistivity <103 ohm-cm
• Delrin* 300AS; Acetal with Carbon fibre
Surface resistivity 103 ohm/sq
Volume resistivity 103 ohm-cm
• Zytel* CDV 595; Nylon 6.6
Surface resistivity 103 ohm/sq
Volume resistivity 103 ohm-cm
• Zytel* EMX 503; FR-Nylon
Surface resistivity 1 ohm/sq
Volume resistivity 102 ohm-cm
• RTP EMI-261H; Nylon 6.6 with stainless steel
Surface resistivity 105 ohms/sq
Volume resistivity 1.0 ohm-cm
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Materials’ comparator
Material
Crastin* S600
Crastin* S650FR
Crastin* SK645FR
Delrin* 500P
Durolon* (X) 2200
Ineos 100-GA12
Rynite * FR530L
Ryton* R4-200
Zenite* 6130 WT
Zytel* HTN 51G35 HSL
Zytel*HTN FR51G35L
Zytel* 101L
Zytel* FR7026VOF
Zytel* FR70G25VO
RTI (0.8mm)
Electrical
RTI (0.8mm)
Mech.with impact
HTD
(1.8MPa)
UL 746 A
PLC level
CTI
Volt
130
130
140
50
80 (1.5)
65 (1.5)
150
220
240
150
140
130
130
130 (1.5)
115
130
125
50
80 (1.5)
65 (1.5)
150
200
240
125
120
75
95
105 (1.5)
60
65
210
115
132
55
224
>260
265
264
255
80
75
244
2
2
2
0
2
0
2
4
0
1
0
0
2
>600
225
250
>600
275
>600
250
150
150
>600
500
>600
575
325
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UL94 (mm)
HB (1.5)
V-0 (0.8)
V-0 (0.8)
HB (0.8)
V-2 (1.5)
HB (1.5)
V-0 (0.35)
V-0 (0.39)
V-0 (0.41)
HB (0.8)
V-0 (0.8)
V-2 (0.8)
V-0 (0.82)
V-0 (0.5)
Glow wire
(mm)
750 (3)
960 (1)
960 (1)
550 (1)
750 (2)
960 (0.8)
960 (4)
960 (1)
750 (1)
960 (1)
960 (2)
960 (0.8)
850 (1.6)
A Polymer for Every
Application
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