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BASF has developed high-flow Ultrason D 1010 G6 U40. The blend based on polyethersulfone (PESU) is optimized to meet special needs for easy injection molding of energy-efficient parts in data and energy transmission, smart electronics and e-mobility.

Because of its flowability at lower processing temperatures, the BASF thermoplastic gives manufacturers greater flexibility when designing sophisticated switches, circuit breakers and sensors as well as insulated-gate biopolar transistors and semiconductor parts like burn-in test sockets.

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According to BASF, Ultrason D 1010 G6 U40 shows stable electrical properties at elevated temperatures with a high relative thermal index (RTI) and a higher comparative tracking index (CTI) than polyetherimide (PEI) and polyphenylenesulfide (PPS). With the new blend, injection molders can reduce the melt temperature by 12.5% compared to a standard PESU.

Ultrason D 1010 G6 U40 (right) has a better flowability than the standard PESU Ultrason E 2010 G6 (left) at lower processing temperatures. It achieves a spiral flow length of up to 3.5 cm at 0.5-mm thickness. Source: BASF

The low-viscosity Ultrason D achieves a spiral flow length of up to 3.5 cm at 0.5 mm thickness with a melt temperature of 315°C and a mold temperature of 160°C. When compared with an unreinforced PESU, the 30% glass fiber-filled grade molded at 360°C shows the same flowability. This enables smaller and thinner parts, saves assembly space and thus leads to greater design freedom for compact electronic assemblies.

Ultrason D 1010 G6 U40 is also characterized by high thermal stability, low water uptake and improved electrical properties like dielectric strength. It is equipped with a nonhalogenated flame retardant. In in-house tests it was rated V-0 at 0.4mm (UL 94) and reached PLC 3 with a CTI of 200V (according to IEC 60112).

Ultrason is the trade name for BASF’s product range of polyethersulfone
(Ultrason E), polysulfone (Ultrason S) and polyphenylsulfone (Ultrason P). The thermoplastic is used to manufacture water filtration membranes and components for the automotive and aerospace industries.