SABIC, a global leader in the chemical industry, is showcasing here at PCIM Europe 2025, in Hall 7, Booth 140, high-heat specialty thermoplastics well suited for demanding electrical applications, including components used in electric vehicles (EVs). The company’s exhibit features Nichicon Corporation capacitors made with ultra-thin Elcres HTV150 dielectric film. These advanced film capacitors for AC-DC inverters can operate at high temperatures up to 150°C with minimal derating of applied voltage (V), which will be discussed in two technical presentations during the event. Also, SABIC is launching a new extrusion grade of Ultem resin with productivity and other advantages over incumbent materials used in magnet wire insulation for EV motors.
“Higher voltages are a common theme across electrical applications from connectors and capacitors to wire and cable,” said Sergi Monros, vice president, SABIC Polymers, Specialties BU. “While high voltages can increase operational efficiency, they present challenges. SABIC continues to lead and innovate in this space. Our specialty materials perform well under exposure to high voltages, high temperatures and harsh conditions, helping customers deliver next-generation electrified components.”
Minimizing voltage derating in film Capacitors
Exposure to elevated temperatures can significantly lower the rated voltage of polymer film capacitors. For example, the rated voltage for capacitors made with biaxially oriented polypropylene (BOPP) film may be reduced by up to 50 percent at 125°C or above, requiring thicker gauges to compensate. However, recent testing by Nichicon showed that capacitors made with SABIC’s Elcres HTV150 dielectric film experienced minimal derating (4.8 percent at 130°C and 14 percent at 150°C). SABIC is displaying this dielectric film and sample Nichicon capacitors at its booth.
SABIC’s Chief Scientist Adel Bastawros, Ph.D., is speaking on these voltage derating test results from Nichicon at the E-Mobility & Energy Storage Stage (Nuremberg, Hall 6, 220) on Tuesday, May 6 at 15:00 CET, and at the PCIM Conference (Athen Stage) on Thursday, May 8 at 14:00 CET. His presentation, titled “HTV150 Dielectric Film for High Heat DC-Link Capacitors with Minimal Derating of Operating Voltage,” is based on a technical paper co-authored with experts from SABIC and Nichicon.
Improving magnet wire insulation
Demands for faster charging and greater range have led to the development of 800V EV electric traction motors. The high-voltage e-motors require magnet wires with improved insulation. Compared to extruded polyether ether ketone (PEEK) insulation, SABIC’s new Ultem resin requires no primer and can deliver low and stable Dk at 220°C at up to 30 percent thinner gauges, helping to reduce overall weight and save space. In contrast to thermoset polyimide (PI) enamel coatings, the SABIC resin avoids the use of solvents that emit volatile organic compounds (VOCs), which can pose regulatory challenges. The new Ultem exhibiting insulated magnet wire using the new Ultem material at its booth. The new Ultem resin is available for trialing.
Showcasing solutions for diverse electrical applications
SABIC is displaying several other electrical components, including a hybrid metal-plastic DC-DC converter housing for EVs that significantly cuts weight and costs vs. an all-aluminum design. Another EV application is a fast charging unit featuring multiple SABIC materials. Also on display are stationary energy storage applications, including enclosures and electrolyzer frames. Other highlights of the company’s exhibit are Ultem and Noryl resins and LNP copolymers and compounds with a high comparative tracking index (CTI), which is important in situations where electrical components are exposed to harsh environments or contaminants and high voltages.
PCIM Europe 2025 is being held in Nuremberg, Germany, May 6-8, 2025.
