Four major application scenarios of PPS in the field of new energy vehicles

As we all know, some new energy vehicles needs to be equipped with custom lithium battery pack. Let me introduce four major application scenarios of PPS in the field of new energy vehicles.

Polyphenylene sulfide (PPS) is an aromatic semi-crystalline special polymer. According to Market.US estimates, the global PPS market will exceed US$1.4 billion in 2022, of which automotive applications will account for more than 34%. By 2032 , the market size is predicted to reach US$3.3 billion, with the Asia-Pacific market share accounting for over 40% of the global market.

PPS has good thermal oxygen aging resistance and can ensure the stability of mechanical strength at extremely high temperatures. Parts made with PPS can work for a long time in harsh temperature environments without failure. It is an important polymer material in the field of new energy vehicles.The application scenarios of PPS in the area of new energy vehicles include explosion-proof custom lithium battery pack covers, busbars and terminal connectors in motor electric drive devices, electronic water pumps, electronic oil pumps, etc.

PPS special material application scenario 1: pole gasket on explosion-proof battery cover

The custom lithium battery pack explosion-proof cover has two functions. The first is to ensure stable charging and discharging – the resistance value is stable within the operating temperature range. In addition, safety needs to be ensured – the battery will fail due to high temperature, the custom lithium battery pack cover will rupture, and the pressure will be released to prevent explosion. PPS material is mainly used for plastic sheets on the positive and negative electrodes of custom lithium battery pack explosion-proof covers.

Explosion-proof battery cover has overall requirements for pole gaskets:

Excellent chemical resistance, especially corrosion resistance from battery pack fluid.
Good bonding force between plastic and metal – the bonding force between aluminum pole and plastic is strong and stable;
The thermal expansion coefficients of aluminum poles and plastics are close to each other.

Considering the above factors, PPS is the most suitable material for pole gaskets.

Positive post gasket (conductive PPS) functional requirements:

The resistance value is 10-10000 ohms. The smaller the resistance value fluctuation range, the better.
The pole will not sink during the laser welding process. The surface of the product does not bulge or collapse.
High and low temperature tests, the product does not crack.

Negative pole gasket (conductive PPS) functional requirements:

Withstand voltage value>1500V.
The pole will not sink during the laser welding process. The surface of the product does not bulge or collapse.
High and low temperature tests, the product does not crack.

PPS special material application scenario 2: electric drive system

The drive motor converts the battery’s electrical energy into mechanical energy and is the direct source of vehicle power. It mainly consists of a stator, a rotor, a casing, a connector, a resolver, etc. The key points of motor technology are the stator and the rotor.

Among them, connectors, stators, rotors and other components are the “specialties” of PPS modified plastics. In addition, the most critical core module of the inverter in the electronic control system: IGBT (Insulated Gate Bipolar Transistor) will also use PPS materials.

PPS has excellent comprehensive properties such as high mechanical strength, high temperature resistance, high flame retardancy, strong chemical resistance, flame retardancy, high crystallinity, good thermal stability, high mechanical strength, and excellent electrical properties, so many components can Saw PPS.

Specific application scenarios: copper busbar, BUSBAR, etc.

Specific application scenarios:

AC/DC bus
Motor terminal connector

Specific application scenario: IGBT module housing

Due to the long verification cycle and high technical and reliability requirements for automotive-grade IGBT modules, selecting appropriate IGBT module materials is also a critical step.

The electronic water pump consists of a pump casing, an impeller, a sealing ring, a motor casing, an electrical plug, a motor assembly, a bearing, a rotor, a controller, a controller base, a back cover, and fixing bolts.

The water pump casing is required to have strong bonding strength with metal, antifreeze resistance, high strength, high welding line strength (to avoid product cracking during storage), hydrolysis resistance, and the use of PPS material to meet its material requirements, injection molding, easy processing, and structural stability. Strong and not easily deformed.

The water pump impeller is made of PPS injection molding, which is characterized by high strength, flame retardant and high temperature resistance, high toughness, dimensional stability, and long service life. The water pump rotor is molded by PPS injection molding, which has the characteristics of high wear resistance and high strength.

Specific applications: electronic water pump housing, electronic water pump waterproof sleeve, electronic water pump impeller

Electronic water pump housing

The electronic water pump housing is constantly exposed to coolant and thermal circulation, so to ensure excellent strength, its material must have low moisture absorption and heat resistance.

Electronic water pump waterproof sleeve

Strict dimensional control and excellent surface appearance are the most important features of electronic water pump waterproof sleeves. These properties allow the baffle to withstand mechanical stress and exposure to glycol.

Electronic water pump impeller

Electronic water pump impellers must have excellent dimensional control accuracy, low moisture absorption and high mechanical strength to be continuously exposed to 140°C coolant for up to 2,000 hours.

As the core product of new energy vehicle electric drive technology, electronic oil pumps are mainly used for cooling the drive motor system to meet the more precise temperature control needs of hybrid vehicles and pure electric vehicles.

Special PPS material solutions for electronic oil pumps need to meet the performance requirements of electronic oil pumps such as high and low temperature resistance, chemical corrosion resistance, hydrolysis resistance, and high dimensional stability.

Summarize

In summary, PPS is widely used as a structural polymer material due to its excellent high temperature resistance, corrosion resistance, radiation resistance, flame retardancy, balanced physical and mechanical properties, excellent dimensional stability and excellent electrical properties. It has been successfully applied in new energy vehicles and other fields.

If you have any question, please feel free to contact us:

Name: Dawn Zeng (Director)
E-mail address: sales@himaxelectronics.com