Solutions
for EV batteries
What is XYRON™?
XYRON™ is polymer alloy combining polyphenylene ether (PPE) with other resins. Asahi Kasei’s The XYRON™ family, which Asahi Kasei has been producing since 1979, boasts an extensive track record—occupying a key role in the history of engineering plastics—and today encompasses an extensive lineup of polymer alloys.
XYRON™ materials offer multiple excellent physical properties. In addition to their outstanding heat resistance, they boast flame retardance, electrical insulation property, good dimensional stability, and hydrolysis resistance, as well as low specific gravity. These polymer alloys combine the advantages of PPE with the specialized properties of various other plastics to yield unique functional properties.
XYRON™ resins have a high oxygen index (a measure of the volume of oxygen required for burning), making them highly flame retardant. In the figure below, a flammability test was conducted using the burner and flame used in UL's flammability test. Under unique conditions, XYRON™ was able to confirm the high flame retardancy.
Case studies: Applications of XYRON™ for EV batteries
- Intercell spacer: XYRON™ 340Z, TF series
The intercell spacer, which is an insulating component used between battery cells, is made of XYRON™ 340Z, which has excellent tracking resistance, hydrolysis resistance, acid/alkali resistance, and long-term stable physical properties, and in addition to these characteristics, it also has oil resistance. We suggest the use of PP/PPE Alloy XYRON™ TF series, which has chemical resistance.
Good thin wall formability contributes to space saving and weight reduction. Furthermore, it has excellent creep properties and flame resistance (non-halogen), contributing to vehicle safety.
- Bus bar cover:XYRON™ 440Z, 443Z
If weight reduction and dimensional stability are important for insulating protective covers for conductors that carry high voltage and large current, we recommend XYRON™ 440Z and 443Z, which have thin wall formability, insulation properties, and heat resistance.
There is also an oil resistance XYRON™ T series that is easier to handle.
- Connector:XYRON™ 644Z
XYRON™ 644Z is used for connectors in automotive battery systems.
Resin materials must be highly reliable to comply with the stringent automotive OEM standards demanded by LV214 and USCAR.
XYRON™ 644Zoffers outstanding flame retardance (UL 94 V-0, 5VA), long-term stability of physical properties (UL746B RTI 125°C), tracking resistance (CTI PLC=2), weather resistance (UL746C f1), and other excellent features.
These superior properties have earned XYRON™ 644Z an extensive track record of use in junction boxes for solar-power generation systems and other similar applications. (Click here to learn more about solar-power generation.)
The same features have also led to XYRON™ 644Z being chosen by a large Chinese battery manufacturer for use in automotive battery connectors.
- Peripheral components for fuel cell stacks:XYRON™ 500H
XYRON™ 500H for the peripheral components of fuel cell stacks. Asahi Kasei recommends
This material features low elution (of ions, oligomers, and other species) and excellent resistance to heat, water, and acid, and their physical properties exhibit minimal degradation upon long-term immersion in liquids.
- Nickel metal hydride battery cell case:Flame-retardant XYRON™ grades
XYRON™ grades for NiMH battery-case components are lower in weight than the metals conventionally used for battery cases, and Asahi Kasei has developed these materials to feature the properties required for battery-cases applications:Flame-retardant
low weight (low specific gravity), alkali resistance, gas-barrier strength, and resistance to metal degradation.
Also, as part of Asahi Kasei’s lineup of ”Contribution through Business Activities” products, these products help to reduce CO2 when in use.