On July 21, 2017, in Shanghai, special chemicals company LANXESS announced the launch of a new PBT alloy material called Pocan AF4130, developed in collaboration with Hella Hook Group from Lippstadt, Germany. This innovative composite material is designed for use in battery housing components, specifically for Battery Management Units (BMUs) and Dual Battery Detection Units (CMUs). The material combines polybutylene terephthalate (PBT) with acrylonitrile-styrene-acrylate copolymer (ASA), reinforced with 30% glass fiber and a halogen-based flame retardant.
According to Marc Marbach, Sales Director of the High Performance Materials (HPM) business unit at LANXESS, the key advantage of this material lies in its extremely low warpage and shrinkage, along with excellent flame resistance. "We believe this material has significant potential in precision parts for vehicle batteries," he said. The development process—from initial concept to full-scale production—took just two and a half years, highlighting the efficiency and collaboration between LANXESS and Hella.
The BMU and CMU housings are used in lithium battery systems for a small German car, featuring complex geometries and large flat surfaces. The design allows for individual injection molding of parts, reducing overall costs. Importantly, the dimensional stability of Pocan AF4130 ensures that connector pins remain straight when mounted on printed circuit boards, meeting tight tolerance requirements.
In terms of safety, the material has achieved UL 94 V-0 (0.75 mm) rating and meets UL 94 5VA (1.5 mm) standards. It is also UL r1 certified for outdoor use, offering resistance to UV radiation and water. This makes it suitable not only for battery housing but also for electronic components like photovoltaic plugs and sockets.
LANXESS conducted thermal desorption analysis according to VDA 278, confirming the material's low surface emissions, which makes it ideal for automotive interior applications where low volatility is essential. Additionally, the material demonstrates excellent resistance to common battery electrolytes, as well as fuels, lubricants, and cleaning agents. Load tests under DIN EN 22088-3 showed no significant cracks after 1,000 hours of exposure, proving its durability.
To support the development of these components, LANXESS provided comprehensive services through its HiAnt Customer Service Pack. This included optimized component design, CAD modeling, and mold flow analysis data to assist in injection molding trials. The company also performed ion chromatography to assess halide content and tested odor levels according to VDA 270.
Overall, Pocan AF4130 represents a major advancement in materials for electric vehicle battery systems, combining performance, safety, and sustainability in a single solution.
The castings produced by the Silica Sol Casting process have high dimensional accuracy and can reach the CT4-8 level specified in GB/6414-1986. The surface roughness value is low, which can reach RA0.8-6.3μm. No machining; the silica sol casting process also produces castings with more complex geometries
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