Horizons Expanding the Possibilities for Challenging E&E Components with Ultrason® D Specialty Plastic
Horizons For challenging electrical and electronic (E&E) components that demand superior performance, BASF has developed the high-flow Ultrason® D 1010 G6 U40. This advanced thermoplastic blend, based on polyethersulfone (PESU), is engineered to address the unique needs of manufacturers seeking efficient injection molding solutions for energy-efficient parts in data transmission, smart electronics, and e-mobility. Horizons The innovative material not only ensures ease of processing but also provides enhanced design flexibility for complex components such as switches, circuit breakers, sensors, insulated-gate bipolar transistors (IGBTs), and semiconductor parts like burn-in test sockets.
Enhanced Flowability and Energy Efficiency
One of the standout features of Horizons Ultrason® D 1010 G6 U40 is its remarkable flowability, even at lower processing temperatures. Compared to standard PESU, this new blend allows injection molders to reduce the melt temperature by 12.5%, leading to significant energy savings. This advantage is critical in today’s manufacturing environment, where sustainability and cost efficiency are paramount.
The improved flow characteristics also enable the production of smaller, thinner components without compromising mechanical or electrical performance. This is Horizons particularly advantageous for compact electronic assemblies, as it allows manufacturers to save valuable assembly space while maintaining the integrity of their designs.
Superior Electrical Performance and Thermal Stability
Horizons Ultrason® D 1010 G6 U40 is optimized for high electrical and thermal performance, making it an ideal material for demanding E&E applications. Its electrical properties remain stable even at elevated temperatures, thanks to a high relative thermal index (RTI) and a higher comparative tracking index (CTI) than competing materials such as polyetherimide (PEI) and polyphenylenesulfide (PPS). These attributes ensure that components made from Horizons Ultrason® D 1010 G6 U40 can withstand extreme conditions while maintaining exceptional dielectric strength.
Additionally, the thermoplastic blend is equipped with a non-halogenated flame retardant, achieving a UL 94 V-0 rating at 0.4mm thickness in in-house testing. It also meets PLC 3 standards with a CTI of 200V (according to IEC 60112), which supports the miniaturization of E&E components by reducing creepage and enhancing insulation compared to traditional materials.
Optimized Processing and Mechanical Strength
The new Ultrason® blend retains the superior chemical and high-temperature resistance characteristic of PESU while offering additional benefits in processing and mechanical performance. It demonstrates better flowability than the standard PESU Ultrason® E 2010 G6, even at lower processing temperatures. Specifically, the low-viscosity Ultrason® D achieves a spiral flow length of up to 3.5cm at a thickness of 0.5mm when processed at a melt temperature of 315°C and a mold temperature of 160°C.
In comparison, a 30% glass fiber-filled grade molded at 360°C displays the same flowability as unreinforced PESU, highlighting the material’s efficiency in processing. This feature is crucial for applications requiring intricate component designs, as it facilitates the production of more complex geometries while maintaining mechanical strength and durability.
Meeting the Evolving Needs of the E&E Industry
The development of Ultrason® D 1010 G6 U40 aligns with the evolving demands of the electrical and electronics industry, where manufacturers are continuously seeking materials that enhance efficiency, safety, and sustainability.
“If you want to develop energy-efficient electronic devices with special demands on electrical and mechanical performance, then our new Ultrason® D is a clever choice,” says Kazuhiro Kida from global business development Ultrason® at BASF. “It benefits from the excellent properties of our established polyethersulfone Ultrason® E while offering optimized E&E performance, outstanding flowability, and the sustainable usage of processing energy. This opens up new possibilities for e-mobility and consumer electronics parts. It also contributes to higher safety for applications with increased voltage and data rates under harsh operating conditions.”
By leveraging the benefits of Ultrason® D 1010 G6 U40, manufacturers can enhance the robustness, durability, and reliability of both current and next-generation E&E components. This material supports the advancement of digitalization, big data, and e-mobility by meeting the increasing performance requirements of modern electronics.
Broad Applications Across Industries
Ultrason® is BASF’s flagship brand for high-performance thermoplastics, including polyethersulfone (Ultrason® E), polysulfone (Ultrason® S), and polyphenylsulfone (Ultrason® P). These materials are widely used across multiple industries due to their exceptional mechanical, thermal, and chemical properties.
Beyond electrical and electronic applications, Ultrason® thermoplastics play a crucial role in manufacturing water filtration membranes, durable household and catering products, and lightweight automotive and aerospace components. Their ability to substitute thermosets, metals, and ceramics in many applications makes them an indispensable material choice for engineers seeking high-performance solutions.
Sustainability and Future Outlook
The introduction of Ultrason® D 1010 G6 U40 underscores BASF’s commitment to sustainability and innovation in material science. By reducing processing energy requirements and enabling the production of more compact and efficient electronic components, this material contributes to a greener manufacturing landscape.
Looking ahead, BASF continues to invest in the research and development of advanced polymers that meet the increasing demands of various industries. The growing trend of miniaturization in electronics, coupled with the need for sustainable and energy-efficient materials, will drive further innovations in high-performance thermoplastics.
With the development of Ultrason® D 1010 G6 U40, BASF provides manufacturers with an advanced solution for tackling the challenges of modern E&E component design. By combining high flowability, superior electrical and thermal properties, and exceptional mechanical strength, this new PESU blend enables the production of more compact, efficient, and durable electronic components.
As industries continue to push the boundaries of technology, materials like Ultrason® D 1010 G6 U40 will play a vital role in supporting the next generation of electronic devices. Whether in data transmission, smart electronics, or e-mobility applications, this innovative thermoplastic is set to redefine possibilities in E&E component manufacturing.
