BASF has introduced a specialty plastic, Ultrason D 1010 G6 U40, a polyethersulfone (PESU) blend designed to meet the evolving demands of the electrical and electronics (E&E) industry. This new material offers exceptional flowability, stable electrical performance, and significant sustainability benefits, opening up new possibilities for challenging E&E components.

The Ultrason D 1010 G6 U40 blend is engineered to facilitate easy injection molding of energy-efficient parts crucial for data and energy transmission, smart electronics, and e-mobility. Its superior flowability at lower processing temperatures grants manufacturers unprecedented design flexibility for intricate components such as sophisticated switches, circuit breakers, sensors, IGBTs, and semiconductor parts, including burn-in test sockets.

A key advantage of Ultrason D 1010 G6 U40 is its ability to reduce melt processing temperatures by 12.5% compared to standard PESU, translating to significant energy cost savings without compromising flowability. This sustainability aspect aligns with the growing industry focus on eco-friendly manufacturing practices.

The material exhibits stable electrical properties at elevated temperatures, boasting a high relative thermal index (RTI) and a comparative tracking index (CTI) of 200V, surpassing the performance of polyetherimide (PEI) and polyphenylenesulfide (PPS). This enhanced electrical performance is crucial for applications requiring reliable insulation and minimal creepage.

Ultrason D 1010 G6 U40 combines the inherent chemical and high-temperature resistance of PESU with high stiffness, strength, and ease of processing. Its low viscosity enables a spiral flow length of up to 3.5cm at 0.5mm thickness with a melt temperature of 315°C and a mold temperature of 160°C. Compared to unreinforced PESU, the 30% glass fiber-filled grade achieves similar flowability at a lower processing temperature of 315°C compared to 360°C. This allows for the production of smaller, thinner parts, saving assembly space and enabling greater design freedom for compact electronic assemblies.

Furthermore, Ultrason D 1010 G6 U40 is characterized by high thermal stability, low water uptake, and improved electrical properties, including high dielectric strength. It is formulated with a non-halogenated flame retardant and has achieved a V-0 rating at 0.4mm (UL 94) and PLC 3 (IEC 60112). These properties support the miniaturization of E&E parts, offering superior insulation and reduced creepage compared to traditional materials.

Ultrason D 1010 G6 U40 joins BASF’s comprehensive Ultrason portfolio, which includes Ultrason E, Ultrason S, and Ultrason P. These high-performance thermoplastics are utilized in various applications, from water filtration membranes to automotive and aerospace components, offering a viable alternative to thermosets, metals, and ceramics.