BASF is expanding its engineering plastics offerings for the electric and hybrid vehicle market. Its Ultramid and Ultradur materials are available for vehicle-interior and -exterior high-voltage plug-in connectors. The polyamide and polybutylene terephthalate grades are said by the company to meet flame retardant, color stability, mechanics and electrical isolation demands. Automotive manufacturers may benefit by saving on weight and installation space around the battery and by improving safety.

An example is connectors for hybrid and electric vehicles that TE Connectivity, Schaffhausen (Switzerland) developed from various Ultramid grades for automotive companies in collaboration with BASF. The BASF polyamide is color stable and resistant to thermal aging, the company says. Particularly in the sensitive range of high voltages, color-coding of components is safety-relevant and must remain highly visible for at least 10 years, BASF says. The company optimized the connector locks using its simulation tool Ultrasim to predict the lock-in behavior of the component, enabling production time and cost savings.

The globally available plastic grades pass IEC standard 62196-1 tests and glow wire test according to IEC 60695-2-11 at 850°C for parts made from isolating matter holding conducting parts, and at 650°C for all other parts made from isolating matter. The materials for plug-in connectors close to the battery are resistant to high temperatures and coolants and are equipped with flame retardant, if necessary.

Materials used for plug-in connectors in the charging system also feature impact strength and creep resistance and offer isolation properties. The portfolio includes plastics that contain halogen-free flame retardant and comply with the Restriction of Hazardous Substances Directive (RoHS).