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SABIC unveils PP-based flame retardant resins for electric vehicle battery pack components

Source:Adsale Plastics Network 2023-07-19

SABIC introduces SABIC PP compound H1090 resin and STAMAX 30YH611 resin, two breakthrough materials suitable for sheet extrusion and thermoforming that offer a unique alternative to traditional sheet metal forming, compression and injection molding, allowing forming large, complex structural parts.


These new products are 30% glass fiber-reinforced, intumescent, flame retardant (FR) materials, based on PP, and can be used for electric vehicle (EV) battery pack components such as top covers, enclosures and module separators. Both grades offer very good thermal barrier properties to help delay or contain thermal runaway propagation.


Furthermore, the extrusion and thermoforming of these materials offer design, system cost, inherent thermal and electrical insulation and weight advantages when compared to stamped sheet metal.


Compared to injection molding of thermoplastics and compression molding for thermosets, which requires expensive tooling and equipment, extrusion and thermoforming can be more cost-effective and efficient for several cases.

EV battery

SABIC launches two PP-based, intumescent FR materials suitable for extruding and thermoforming large, complex EV battery pack components.

SABIC’s development and validation of these new materials is made possible by BLUEHERO, an initiative that supports the automotive industry’s mission to create reliable, safe and efficient EVs, with an emphasis on helping optimize structural battery components.


BLUEHERO leverages, among other things, the company's knowledge of and expertise in large part molding, compression molding, thermoforming and advanced injection molding.

Mechanical and fire safety performance validated


SABIC has validated the mechanical and fire safety performance and the manufacturability of SABIC PP compound H1090 resin and STAMAX 30YH611 resin in EV battery applications with complex geometries, both in its labs and with customers.


The company introduced that these materials not only provide new options for the replacement of sheet metal or thermosets in final applications, they can also be used to create prototypes to determine the feasibility of investing in injection molding tools.


Both short glass fiber-reinforced SABIC PP compound H1090 resin and long glass fiber-reinforced STAMAX 30YH611 resin feature a distinct combination of intumescence for fire safety and balanced stiffness and ductility. Exposing these materials to vertical and horizontal flames at 1200°C for 10 minutes demonstrates good flame-retardant behavior.


Efficient charring and intumescence keep the temperature of the reverse side of parts lower than 210°C and help prevent burn-through. Intumescence is enhanced by non-brominated/non-chlorinated FR that meets the UL94 V0 standard at 1.5 mm.


In addition to stiffness, strength and impact resistance over a wide temperature range, key properties of SABIC PP compound H1090 resin and STAMAX 30YH611 resin include dimensional stability, low coefficient of thermal expansion (CTE) and good creep resistance.

Electric vehicles
Battery pack

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