Challenges For Future Powerplant Coolant Systems

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1 Challenges For Future Powerplant Coolant Systems Steven Mok, Karla Butler, Terrence Cressy, Paul Kane, Brian Fish (Presented at SPE Auto EPCON, April 28, Sterling Heights, MI)

2 2 Discussion Agenda Water and electricity meet in future thermal management systems Today s challenges for tomorrow s vehicle electrification - Hybrid and plug-in electric vehicles and high-voltage, high heat power modules thermally manage cold starts and high heat electronics - Conserving mass and power in conventional HVAC systems via electrical water pumps/valves/thermostats and electric power systems Why PPA materials for conventional HVAC and electrical thermal management? - The basics: Resistance to hydrolysis and moisture for more cost effective applications such as water inlets/outlets, thermostat housings, electric water pumps, impellers, etc. - Parts integration, including over-molded connectors - Cost and manufacturing economics are inseparable topics

3 Thermal Management for Electric Vehicle Safety, Efficiency Opportunities for High Temperature, Dimensionally Stable, LLC Resistant and Electrically Isolative Engineering Thermoplastics 3 Multiple heat exchangers and coolant circuits per vehicle to manage: Li-ion battery (-20C to 60C range), power electronics (up to 150C), conventional HVAC Surge tanks 3 and 4 way coolant valves 3-4 electrical water/coolant pumps (both heat and cool) Heating and cooling Coolant inlets/outlets Exchange fluid systems Hoses, tubing Thermostats Sensors Thermal electrical/electronics High-energy cables and connectors Power control/inverter module housings and connectors Traction Motor encapsulation/insulation Graphic source U.S. Department of Energy

4 4 The basics of PPA for Thermal Management What Can PPA Do and Why?

(Partially) Aromatic (Partially) PPA Aromatic (Fully) Aramid 0% Less Than 55% 55% or More 100%

5 5 PPA FAMILY of Polymers - Provide Chemical Resistance, and High Temperature Performance for thermal management in coolant and electrical systems Polyamide Aromatic Di-Acids Aliphatic Aromatic (Partially) Aromatic (Partially) PPA Aromatic (Fully) Aramid 0% Less Than 55% 55% or More 100% Examples: Zytel PA66 Zytel PA6 Zytel PA612 Zytel HTN53 Zytel HTN51 Zytel HTN52 Zytel HTN54 Other PPA s Kevlar Nomex

6 PPA Retains Properties Well under Humid Conditions, with Good Balance of Toughness, Rigidity and Specific Weight 6 Polymer PA 66 PPA (HTN) PPA (HTN) PPS Glass Content 33% 35% 45% 40% Tensile Strength, MPa DAM 50% RH Elongation, % DAM 50% RH Tensile Modulus, MPa DAM 50% RH 10,500 8,000 12,500 12,500 15,000 15,000 14,000 (Flexural) Notched Izod Impact, kj/m2 DAM 50% RH Specific Gravity

7 7 The basics of PPA for Thermal Management Coolant exposure One sided to two sided exposure

8 8 Zytel HTN PPA In Coolant Coolant Performance - Zerex LLC G05 50% - 130C Tensile Stiffness ISO Tensile Modulus (KPsi) Samples tested at 23C PPA Zytel HTN 51G35HSLR Hydrolytic Stab PPA 33%GR Hydrolytic Stab PA66 33%GR Hrs

9 9 Zytel HTN PPA In Coolant Coolant Performance - Prestone Dexcool LLC 50%,130C Samples tested at 23C Tensile Modulus (KPsi) Tensile Stiffness ISO 527 PPA (45%GR) Zytel HTN 51G45HSLR PPA (35%GR) Zytel HTN 51G35HSLR Hydrolytic Stab PA66 33%GR Hrs

10 10 Zytel HTN PPA In Coolant 250 After Water/Glycol 130ºC Break (MPa) PPS-2 (40% Glass) PPA 35%GR (Zytel HTN 51G35HSLR) PPS-1 (40% Glass) Time of Aging (h)

11 For Coolant Components in Power Electronics PPA Maintains Rigidity and Strength at High Temperatures 11 2,000 Flexural Modulus, kpsi 1,500 1, PPS 40% GR PA66 33% GR PPA (HTN) 35%GR Temperature, C

12 PPA Has Low Creep & Maintains Good Dimensional Stability 12 PA66, 30% glass PPS, 40% glass PPA HTN GF35 PPA - HTN GF45

13 13 Electrical Coolant Pumps, Impellers and Valves PPA Benefits/Features: Weight $avings vs. Aluminum, PPS Cost $avings through Integration Withstand Hot Aggressive Long Life Coolant High Temp Dimensional Stability for Precision No Secondary Operations like De-flashing Good Balance of Rigidity and Toughness

14 PPA Cost Effective Solution to Meet Structural Cooling Components Requirements 14 Properties Retention in Hot Aggressive Long Life Coolants Maintain Rigidity and Strength at Hot and Humid Environment Low Creep at High Temperature for Dimensional Stability Balance of Rigidity and Toughness at Minimal Weight Low mold deposit and flash for molding economics on cycle Welding and over-molding compatibility with PA 66 components

15 15 The basics of PPA for Thermal Management Electrical Parts Integration

16 Map- Controlled Thermostat Housing in PPA HTN PPA Benefits/Features: Excellent Resistance to Coolants @140C. Resist Pressures to 2.

16 16 Map- Controlled Thermostat Housing in PPA HTN PPA Benefits/Features: Excellent Resistance to Resist Pressures to 2.5 Bars Withstand Engine Vibration Stress Maintain Dimensional Stability Cost $avings for Assembly Vibration Welding for 2 HTN Parts Compatibility/Melt Bonding with Lower Cost PA66 Connector Through Overmolding integration

17 17 Electrical/Electronic Thermal Management Challenges and Solutions Sensors - Electrical Friendly resins High-Energy Cables and Connectors high temperature thermoplastic elastomer vulcanates Power Control/Inverter Module Housings and Connectors PPA EF grades Traction Motor Encapsulation / Insulation magnet wire enamels with nano-particle content or wire wrap and slot liners in PI films Overmold Electrical Lead Frames PPA EF grtades

PPA Cost Effective Solution to Meet High Voltage Electrical / Electronics Powerplant Components 18 High Volume Resistivity Retention with Humidity Exposure

18 PPA Cost Effective Solution to Meet High Voltage Electrical / Electronics Powerplant Components 18 High Volume Resistivity Retention with Humidity Exposure >600+ Volts Comparative Tracking Index to Prevent Carbon Tracking High Temperature Strength and Impact Resistance USCAR Class 4 (150 oc) Capable - Heat & Humidity

19 19 DuPont Developed EF (Electrical/Electronic Friendly) Technology with PPA to Meet the High Voltage Needs Polymer Type PPA PPA PA66 PPS Trademark (DuPont) Zytel HTN51 (EF Grades**) Zytel HTN51 Zytel Glass Transition Temp, Tg (oc) Volume Resistance 1 E+11 1 E+9 1 E oc Tracking Index, CTI 600V 600V 400V 150V Applications Structural, Electrical, High voltage Structural, Electrical ** Electrical / Electronics Friendly Structural, Electrical

20 EF (Electrical / Electronic) PPA HTN Grades Maintain Volume Resistivity with Moisture and Temperature 20

21 21 High CTI is Crucial to Minimize Arcing Damage Resin PPA (HTN) - EF 40% GR PPS 30% GR PBT CTI (volts)

22 22 Summary -- Future PowerPlant Coolant Systems + High Voltage PPA - a Cost Effective Material Solution for Achieving Cost and Weight Savings coolant through batteries and power modules Chemical Resistance to Hot Long Life Coolants Maintain Rigidity and Strength under Hot and Humid Conditions Low Creep for dimensional stability Compatible Welding Between Components Made with PPA or Lower Cost PA66 EF (Electrical / Electronics Friendly) Grades of PPA (HTN) Deliver Cost Effective Solutions to High Voltage Electrical Powerplant Components 600+ Volts for Arcing Protection High Volume Resistivity at Hot & Humid Environment for Insulation USCar Class 4 Capable

23 23 Contact your local DuPont representative or log on to plastics.dupont.com and click on the Contact Us button. For questions about our products and how to use them, call us at the following numbers: or International Or visit us at: plastics.dupont.com

24 24 The data listed here fall within the normal range of properties, but they should not be used to establish specification limits nor used alone as the basis of design. The DuPont Company assumes no obligations or liability for any advice furnished or for any results obtained. All such advice is given and accepted at the buyerâ s risk. The disclosure of information herein is not a license to operate under, or a recommendation to infringe, any patent of DuPont or others.. CAUTION: Do not use DuPont materials in medical applications involving implantation in the human body or contact with internal body fluids or tissues unless the material has been provided from DuPont under a written contract that is consistent with DuPont policy regarding medical applications and expressly acknowledges the contemplated use. For further information, please contact your DuPont representative. Copyright 2009 DuPont or its affiliates. All rights reserved. The DuPont Oval Logo, DuPont, The miracles of science, Rynite, Zytel, NOMEX, and KEVLAR are registered trademarks or trademarks of DuPont or its affiliates.

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Hello, I am Paul Kane, the Americas leader for DuPont engineering plastics development activities in vehicle electrification systems.

Hello, I am Paul Kane, the Americas leader for DuPont engineering plastics development activities in vehicle electrification systems. DuPont Automotive Performance Materials to Help Electrify Vehicles DuPont Automotive Webcast hosted by SAE International Oct. 21, 2009 Hitoshi Shioya DuPont Automotive Global Electrical & Electronic Applications