SABIC Introduces Engineering Plastics for Harsh Electrical Conditions at PCIM 2025
- At PCIM Europe 2025, SABIC is featuring voltage derating test results for ELCRES HTV150 film used in Nichicon capacitors, and a new ULTEM resin well suited for magnet wire insulation.
- The company is displaying a range of high-performance materials for diverse electrical applications, from EV converters and fast chargers to stationary energy storage batteries.
At PCIM Europe 2025, SABIC, a world leader in the chemical industry, is exhibiting high-heat specialized thermoplastics that are ideal for demanding electrical applications, such as parts for electric vehicles (EVs), in Hall 7, Booth 140. Capacitors manufactured by Nichicon Corporation using ultra-thin ELCRES HTV150 dielectric film are on display at the firm. Two technical presentations will be held at the event to highlight the capabilities of these new film capacitors for AC-DC inverters, which can function at temperatures as high as 150°C with little derating of applied voltage (V). Additionally, they are introducing a new ULTEM resin extrusion grade that has productivity and other benefits over existing materials used in EV motor magnet wire insulation.
“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, their 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, their resin avoids the use of solvents that emit volatile organic compounds (VOCs), which can pose regulatory challenges. The new ULTEM resin can be used for mono-layer extrusion and requires only one pass, which helps to boost productivity, while enamel requires up to 20 coating passes. 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.
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