Solvay Establishes New Insulating Polymer for High-temperature EV Battery Modules

Xydar LCP G-330 HH is a new liquid crystal polymer grade that increases passenger safety during a battery thermal runaway.

FREMONT, CA: "As automakers are moving from 400V to 800V on next-generation electric vehicles, new regulations in Europe, China, the United States, and other countries are increasing the demand on battery components to withstand temperatures from 300°C to 1000°C for an extended window of up to 15 minutes," states Brian Baleno, Head of Marketing, Transportation at Solvay Materials. Solvay, a global market leader in specialized materials, has introduced a new high-heat and flame retardant grade to its Xydar® liquid crystal polymers (LCP) line, designed to meet crucial safety requirements in EV battery components. The new Xydar® LCP G-330 HH material meets stringent thermal and insulation standards and is designed specifically for battery module plates of electric vehicle models with higher voltage systems.

“Appropriate materials are expected to retain a level of electrical insulation protection that will provide sufficient time for passengers to exit the vehicle in a thermal runaway event. Our new Xydar® LCP grade combines this high safety potential with exceptional processability,” adds Baleno.

Xydar® LCP G-330 HH is a glass-filled LCP for injection molding that can maintain its electrical insulation after 30 minutes of exposure to 400°C. Xydar® LCP is an intrinsically flame-retardant polymer that does not require the addition of halogen or bromine. In addition, it provides remarkable flowability and enables battery designers to create smaller components than is possible with existing battery module insulating materials, such as polycarbonates or aerogels. It has been successfully tested with 100 x 150 x 0.5 mm plates with standard dimensions.

The compatibility of Xydar® LCP with numerous electrical, electronic, and coating applications has been demonstrated. In addition to automotive lighting components, sensors, solenoids, and connections, advanced e-mobility examples include thin-wall slot liners used in the rotor design of an electric drive traction motor.

Solvay's battery solutions already include Solef® PVDF for binders and separators, Ryton® PPS for coolant line connectors and vents, and Amodel® PPA for connectors and busbars, but the addition of Xydar® LCP G-330 HH broadens this offering even more.

The brands Amodel®, Ryton®, Solef®, and Xydar® belong to Solvay.