For challenging electronic and electrical components with special requirements, BASF has now developed the high-flow Ultrason® D 1010 G6 U40.

The optimized polyethersulfone (PESU) blends are designed to meet the specific requirements for energy-efficient components in data and energy transmission, smart electronics, and electric vehicles, enabling easy injection molding.

Compared with standard PESU, the melt temperature can be reduced by 12.5%.

BASF's new thermoplastic products have excellent fluidity at lower processing temperatures. This provides manufacturers with greater flexibility in designing complex switches, circuit breakers, and sensors, as well as IGBT and semiconductor components, such as aging test sockets.

Ultrason® D 1010 G6 U40 exhibits stable electrical performance at high temperatures, offering a higher Relative Thermal Index (RTI) and Comparative Tracking Index (CTI) compared to polyetherimide (PEI) and polyphenylene sulfide (PPS). In contrast to standard PESU, the new blend allows molders to reduce melt temperature by 12.5% while maintaining excellent flowability, thereby saving energy costs.

Backed by the excellent chemical resistance and high-temperature resistance of PESU, the new Ultrason® blends combine high rigidity and strength with good electrical performance and ease of processing. It has better fluidity at lower processing temperatures compared to standard PESU Ultrason® E 2010 G6.

Low viscosity Ultrason® D can achieve a spiral flow length of up to 3.5 cm at a thickness of 0.5 mm, with a melt temperature of 315°C and a mold temperature of 160°C. Compared to unreinforced PESU molded at 360°C, a 30% glass fiber-filled grade shows the same level of flowability. This allows for smaller and thinner parts, saving assembly space and thus providing greater design freedom for compact electronic components.

Support the miniaturization of E&E components through lower crawl distances compared to PEI and PPS.

Ultrason® D 1010 G6 U40 has high thermal stability, low water absorption, and excellent dielectric strength. It is equipped with halogen-free flame retardants and has outstanding electrical RTI. In internal tests, it is rated V-0 (UL 94), with a CTI of 200V (according to IEC 60112), reaching PLC 3. This supports the miniaturization of E&E components, with its creepage distance and insulation performance surpassing that of PEI and PPS used for challenging E&E components to date.

"If you want to develop energy-efficient electronic devices with special requirements for electrical and mechanical performance, then our new Ultrason® D is a wise choice," said Kazuhiro Kida, Global Business Development Director of BASF’s Ultrason® business. "It benefits from the excellent properties of our mature polyether sulfone Ultrason® E, while offering optimized E&E performance, superior flowability, and sustainable use of processing energy. This opens up new possibilities for electric vehicles and consumer electronics parts. It also helps provide higher safety for applications with increased voltage and data rates under harsh working conditions."

Ultrason® D 1010 G6 U40 is part of BASF's Ultrason® product portfolio tailored for the electronics and electrical (E&E) industry. These grades enhance the robustness, durability, and reliability of today's and next-generation E&E components, driving advancements in digitalization, big data, and electric vehicles. They are particularly suitable for scenarios where other plastics cannot meet higher performance requirements.

Ultrason® is the brand name for BASF's polyethersulfone (Ultrason® E), polysulfone (Ultrason® S), and polyphenylsulfone (Ultrason® P) product lines. This high-performance thermoplastic is used in the manufacture of water filtration membranes, fashionable, durable, and safe household and catering applications, as well as lightweight components in the automotive and aerospace industries. The Ultrason® brand is known for its exceptional performance, making it a viable alternative to thermosetting plastics, metals, and ceramics in many applications.