High-Performance Flame-Retardant High-Temperature Nylon: Material Solutions Meeting The High CTI Requirements of New Energy Vehicles

High-Performance Flame-Retardant High-Temperature Nylon: Material Solutions Meeting The High CTI Requirements of New Energy Vehicles

I. Industry Background and Technical Challenges

With the rapid development of new energy vehicles and high-end electronic/electrical equipment globally, the performance requirements for key engineering plastics have evolved from single flame retardancy to a comprehensive performance assessment. In core components such as high-voltage control systems, battery modules, sensors, and connectors, materials must not only excel in flame retardancy (UL94 V-0) but also meet the following critical performance criteria:

• High CTI (Comparative Tracking Index): The ability to resist arc carbonization and short circuits at voltages of 600V and above is crucial for the long-term safety and reliability of electrical equipment.

• High-temperature resistance: A continuous service temperature exceeding 150℃ and short-term heat resistance capable of withstanding high-temperature processes such as reflow soldering.

• High mechanical properties: Including strength, stiffness, and toughness to ensure structural components maintain stable performance under vibration and impact.

• Chemical resistance: Resistance to corrosion from coolants, electrolytes, and other chemicals.

• Good dimensional stability: Low water absorption to ensure minimal changes in size and performance in humid environments.

However, traditional flame-retardant nylons (such as PA6 and PA66) encounter insurmountable technical barriers when attempting to enhance flame retardancy through conventional systems (e.g., bromine-antimony synergies or red phosphorus):

• Large additions of flame retardants to achieve V-0 ratings severely degrade mechanical properties and flowability, reducing impact strength and making injection molding difficult.

• Most flame retardant systems, especially halogen-containing ones, significantly reduce CTI values, making materials unsuitable for high-voltage environments above 600V and posing leakage fire risks.

• In high-temperature and high-humidity conditions, materials are prone to hydrolysis and aging, with a sharp decline in mechanical properties and dimensional stability.

In this context, semi-aromatic high-temperature nylon stands out as an ideal base material due to its unique molecular structure:

• Excellent heat resistance: A heat deflection temperature (HDT) exceeding 280℃ and a continuous service temperature well above 150℃, meeting the most demanding thermal management requirements in automotive and electronic fields.

• Very low water absorption (typically <0.5%): Far lower than PA6/66, ensuring superior dimensional stability and mechanical performance in humid environments, making it suitable for precision structural components.

• Inherent dimensional stability and chemical resistance: Resistance to various chemicals and electrolytes.

• Good electrical properties: Providing a foundation for achieving high CTI through formulation design.

Therefore, developing a composite material based on high-performance nylons such as PA10T, which balances high flame retardancy, high CTI, excellent mechanical properties, and processability, is key to overcoming technical barriers and meeting next-generation design requirements.

II. Innovative Solutions and Technical Highlights

1. Optimized Material Formulation System

To address the multiple performance challenges in high-temperature nylon applications, we have designed a synergistic high-performance composite material system through systematic formulation:

• Base Material Selection

High-temperature nylon is selected as the primary material. Its semi-aromatic chain segments provide excellent heat resistance (HDT > 280℃) and dimensional stability, while its low water absorption (<0.5%) ensures performance retention in humid environments, offering an ideal foundation for high-performance applications.

• Flame Retardant System

An innovative synergistic flame retardant system combining aluminum diethylphosphinate (ADP) and octamethylcyclotetrasiloxane:

• ADP acts in both gas and condensed phases, promoting char layer formation via phosphoric acid generation and releasing inert gases.

• Silsesquioxane forms a protective silicon-carbon layer during combustion, effectively blocking heat and oxygen.

• The synergy achieves UL94 V-0 at 0.8mm thickness with significantly reduced smoke emission.

• Synergistic System

Nano-silica addition delivers multiple benefits:

• CTI values exceed 600V by forming barriers against arc carbonization.

• Enhanced char layer density improves flame retardancy.

• Improved melt strength reduces die drooling during processing.

• Reinforcement System

A hybrid carbon and glass fiber reinforcement scheme:

• Carbon fibers provide exceptional stiffness and electrical conductivity (volume resistivity up to 10³ Ω·cm).

• Glass fibers enhance mechanical properties and reduce costs.

• The dual-fiber system improves strength while maintaining dimensional stability and corrosion resistance.

• Toughening System

A specialized ethylene-acrylate-maleic anhydride terpolymer toughening agent:

• Reactive functional groups bond chemically with nylon end groups.

• Superior impact resistance from -40℃ to 120℃.

• Notched impact strength exceeds 12 kJ/m².

• Stabilization System

A composite thermal stabilizer system including:

• Piperydine photothermal stabilizers: Scavenge free radicals to prevent thermo-oxidative degradation.

• Methyl thiostannate: Inhibits molecular chain scission during processing.

• Synergistic effects ensure stable performance after multiple processing cycles.

2. Key Performance Advantages

• High CTI Performance

CTI values range from 600-675V, surpassing traditional flame-retardant nylons (typically 300-400V). This meets the stringent insulation material requirements of electric vehicle high-voltage systems (800V platforms) and significantly reduces leakage tracking risks.

• Exceptional Flame Retardancy

Achieves UL94 V-0 at 0.8mm thickness with a glow wire ignition temperature (GWIT) exceeding 800℃, suitable for the most flame-retardant demanding applications.

• Balanced Mechanical Properties

• Tensile strength: >180 MPa

• Flexural modulus: >12,000 MPa

• Notched impact strength: >10 kJ/m²

• Combines high strength and stiffness with good toughness.

• Superior Chemical Resistance

Resists oils, coolants, electrolytes, and other chemicals. After 1000 hours of aging at 85℃×85%RH, performance retention exceeds 85%.

• Excellent Processability

Melt flow rate (MFR) is controlled between 15-25 g/10min (325℃/2.16kg), ideal for injection molding complex thin-walled components. Mold shrinkage is stable at 0.2-0.5%, ensuring high dimensional accuracy.

This innovative material system, through the synergistic effects of its components, resolves the contradictions between multiple high-performance requirements, offering a reliable material solution for new energy vehicles and high-end electronic/electrical equipment.

III. Application Fields and Market Prospects

1. Key Component Applications in New Energy Vehicles

This material system shows broad application potential in new energy vehicles, including:

• Battery System Components

• Electrode separator: High CTI (≥600V) and flame retardancy ensure battery group safety in high-voltage environments.

• Battery module bracket: Excellent heat resistance (continuous service temperature >150℃) and dimensional stability support battery group structure and prevent thermal runaway propagation.

² High-voltage connector housing: High strength and stiffness meet structural requirements, with flame retardancy providing safety. Electric Control System Components

• Electrical Control System Components

• Motor controller insulation parts: High CTI ensures electrical safety on 800V high-voltage platforms.

• Power semiconductor support parts: High-temperature resistance and low water absorption guarantee reliability in high-temperature and high-humidity environments.

• Chassis and Body Systems

• Damping and shock absorption parts: Material strength and fatigue resistance enhance vehicle NVH performance.

• Charging port components: Flame retardancy meets international charging standards.

2. Electronic and Electrical Connector Fields

• High-Voltage Connector Systems

• Suitable for vehicle connectors on 800V and above high-voltage platforms.

• Meets international standards such as USCAR-2 and LV215.

• Maintains stable electrical performance in high-temperature and high-humidity environments.

• 5G Communication Equipment

• Base station power device insulation support parts

• High-frequency connector housings: Low dielectric constant and loss factor ensure signal transmission quality.

• Equipment heat dissipation parts: Heat resistance and dimensional stability meet high thermal load requirements.

• Consumer Electronics Field

• Fast charging port components: Meets heat resistance requirements for high-current transmission.

• Smart device structural parts: Thin-wall molding capability suits precision structural designs.

3. Industrial Application Fields

• Energy and Power Equipment

• Photovoltaic inverter insulation parts: Weather and arc resistance meet outdoor usage requirements.

• Wind power equipment connectors: Low-temperature impact resistance and corrosion resistance adapt to harsh environments.

• Automation Equipment

• Robot joint parts: High strength and stiffness meet precision motion requirements.

• Sensor housings: Electromagnetic shielding protects signal transmission.

• Advanced Manufacturing Equipment

• Aerospace connectors: Meets aviation standards such as DO-160.

• Rail transit parts: Certified to fire protection standards such as EN45545.

4. Market Prospects and Development

• Trends Market Size and Growth

According to the latest industry research reports:

The global flame-retardant high-temperature nylon market is expected to reach billions of dollars by 2030, with a compound annual growth rate of 8%.

• The new energy vehicle engineering plastics market is projected to grow at 30%, with high-voltage system materials showing the most significant demand growth.

• The ongoing advancement of 5G infrastructure construction brings new growth opportunities for high-performance materials.

• Technical Development Trends

• Voltage platform upgrades: From 400V to 800V and even 1200V, driving continuous increases in CTI requirements for materials.

• Integrated design: Miniaturization and thin-walled components place higher demands on material processability.

• Sustainable development: Increasingly stringent environmental requirements for halogen-free flame retardancy and bio-based materials.

• Regional Market Characteristics

• Asia-Pacific region: The world's largest new energy vehicle market, accounting for 40% of global demand.

• European market: Strict environmental regulations promote the development of halogen-free flame-retardant materials.

• North American market: Focuses on material performance certification and reliability verification.

• Future Development Opportunities

• New material demands from solid-state battery commercialization.

• Autonomous driving technology driving sensor usage growth.

• Industry 4.0 promoting the expansion of automation equipment markets.

This innovative material system, with its superior comprehensive performance, is becoming a key choice in advanced manufacturing. Its market prospects are extremely broad with the rapid development of new energy and digital technologies.

IV. YINSU Flame Retardants' Technical Advantages

1. Comprehensive High-Temperature Nylon Flame Retardant Solutions

YINSU Flame Retardants, specializing in high-temperature engineering plastics flame retardancy for years, offers a full range of solutions from base flame retardants to composite materials:

• Diversified Product Portfolio

• Red phosphorus flame retardant series: Red phosphorus products like FRP-301Y3, featuring low addition levels, high efficiency, and minimal color impact.

• Organic phosphorus flame retardant series: Organic phosphorus products like WADP-10, combining high thermal stability and excellent flame retardancy.

• Composite flame retardant systems: Specialized formulations tailored to specific application scenarios.

• R&D Capabilities

• Professional R&D team and advanced experimental facilities.

• Established industry-academia-research collaborations.

• Annual R&D investment exceeding 5% of sales revenue.

2. Professional Customization Services

Recognizing the varying material performance requirements across different applications, we offer comprehensive customization services:

• Formulation Customization

• Adjust flame retardant system ratios based on specific application environments and performance requirements.

• Develop pigment systems compatible with special color requirements.

• Optimize material flowability and moldability for different processing techniques.

• Application Technical Support

• Provide material selection guidance and recommendations.

• Assist in resolving processing issues.

• Participate in customer new product development to offer material solutions.

3. Full-Scale Technical Support Services

We deliver end-to-end technical support from concept to mass production:

• Pre-Development Phase

• Material performance testing and evaluation.

• Application feasibility analysis.

• Sample provision and validation.

• Mass Production Support Phase

• Process parameter optimization guidance.

• Quality control standard development.

• On-site resolution of production issues.

• After-Sales Services

• Regular customer follow-ups.

• Rapid response to quality issues.

• Technical upgrade notifications.

4. Robust Quality Assurance System

Quality is our top priority. We have established a comprehensive quality assurance system:

• Certifications and Credentials

• ISO9001 quality management system certified.

• Products compliant with international environmental standards such as RoHS and REACH.

• Expanding series of UL-certified products.

• Quality Control Measures

• Strict screening and inspection of raw materials.

• Full-process monitoring of production.

• 100% performance testing of finished products.

• Traceability System

• Comprehensive product traceability system established.

• Complete production and inspection records for each batch.

• Swift response to customer quality feedback.

V. Conclusion

The successful development of high CTI flame-retardant high-temperature nylon composites marks a significant breakthrough in our engineering plastics flame retardancy technology. This material elegantly resolves multiple performance balancing challenges:

• Significance of Technological Breakthroughs

• Achieves unity between high CTI values and excellent flame retardancy.

• Overcomes the contradiction between high strength and good processability.

• Balances heat resistance and toughness.

• Industry Application Value

• Provides new energy vehicle industry with a safe and reliable material option.

• Supports the high-voltage and miniaturization development of electronic/electrical industries.

• Promotes the upgrading and intelligent transformation of industrial equipment.

• YINSU Flame Retardants' Commitment

As a leading company in the flame-retardant materials field, YINSU Flame Retardants will continue to:

• Increase R&D investment and drive continuous technological innovation.

• Deepen customer collaboration and deliver higher-quality services.

• Enhance product systems to meet diversified market demands.

Enforce strict quality control to ensure product reliability. We believe that through ongoing innovation and service optimization, YINSU Flame Retardants will create greater value for customers and make greater contributions to industry development. Let us work together to advance the technology of flame-retardant materials.