Syensqo’s Amodel? PPA Supreme enables over 25% weight reduction in eDrive clutch, cooling, and lubrication components operating above 150 ℃
Brian Baleno
Director Global Business Development & Program Management: Batteries, E-Motors/eDrive (Torque Transfer), Power Electronics, ePumps, ICE Solutions (Thermal, Fuel, Air)
By: Greg Poterala, Stefano Montani, Coleman Hellyer, Luigi Marino, Brian Baleno?
Allegheny Performance Plastics: Greg Shoup?
As OEMs seek greater efficiency in battery electric vehicles (BEVs), electric drive units (eDrive or EDU) are being developed as integrated systems which combine the gearbox, electric motor (eMotor), and power electronics into a single unit. This level of integration favors direct oil cooling over indirect ethylene glycol/water cooling. Additionally, the fluid is functionalized to accomplish the same. Taken together, the combination of temperature and chemical resistance to oil-based thermal management fluids like automatic transmission fluid (ATF) requires materials that can operate at 150 ℃, retain mechanical properties after exposure to ATF, and also provide dimensional stability.?
Within an eDrive system, there are multiple components that require a PPA material capable of operating above 150 ℃. Some examples include: clutch components, stator cooling guides, lubrication screens, busbars, high voltage connectors.
Amodel? Supreme PPA was developed to address several key needs in the electric powertrain market. First, as a material capable of retaining mechanical properties above 150 ℃ and providing greater dimensional stability than conventional PPAs such as PA6T/6I or PA6T/66. The main driver here was to replace metal in powertrain components operating above 150 ℃ which is higher than the glass transition temperature (Tg) of traditional PPAs (Tg of PA6T/6I = 135 ℃). Amodel? Supreme PPA is designed to have a best-in-class Tg of 165 ℃.
Figure 1 below shows how Amodel? Supreme PPA retains greater mechanical strength after heat aging at 150 ℃ for 5,000 hours. Similarly, Figure 2 reveals the significant difference in non-ambient tensile properties between Amodel? Supreme PPA (A-9XXX) and Amodel? PA6T/6I (A-8XXX).
Figure 1: Mechanical Properties Retention of PPAs at 150 ℃ for 5,000 hrs
?? AE-9933 (Amodel? ?Supreme PPA)
?? AE-8930? (PA6T/6I)
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?? AE-6133? (PA6T/66)
Figure 2: Tensile Properties Comparison at 100 ℃ and 150 ℃
Amodel? Supreme PPA was evaluated in BEV oil cooling fluid after prolonged exposure. Figure 3 below highlights the excellent chemical resistance of Amodel? Supreme PPA with more than 85% of its tensile strength retained after aging at elevated temperatures.
Figure 3: Mechanical Properties Retention of Amodel?? Supreme PPA at 150 ℃ for 1,500 hrs in EV oil cooling fluid
Two additional benefits of Amodel? Supreme PPA over other PPAs like PA6T/6I are a lower coefficient of thermal expansion (CLTE) as shown in Figure 4 below and better resistance to moisture uptake, as shown in Figure 5.
Figure 4: CLTE Comparison of Amodel?? Supreme PPA (A-9950) vs. Amodel?? PPA (A-8950 6T/6I)
Figure 5: PPA Moisture Absorption Data Comparison
In summary, Amodel? Supreme PPA is a material capable of maintaining mechanical performance for eDrive system components. This new PPA provides best-in-class mechanical properties above 150 ℃, chemical resistance, and dimensional stability. Potential applications include clutch, lubrication screens, and stator cooling components. If you are interested in learning more about these solutions, please contact us.