Raw Materials, Additives and Masterbatches

damage its internal insulation, thermal management is a crucial performance factor for e-motors for electric vehicles – the design of the insulating system is, clearly, instrumental. In search of the "dream" slot liner insulator, Victrex engineers undertook a simulation of replacing a 250- micron meta-aramid-PET-laminate slot liner material with 150-micron PEEK polymer based APTIV™ film. This simulation used a 40% thinner and more thermally conductive thermoplastic slot liner film which was shown to enable improved heat flow from the wire windings to the stator iron and outer-water-jacket cooling system. Additional simulations have shown the excellent thermal conductivity of APTIV™ film which enables improved thermal management and reduction of peak winding temperatures by 2-3°C compared to traditional laminates and helps the e-motor stay cool. With improved thermal management and thinner slot liners the simulations observed a potential increase in copper density (i.e. the slot-fill factor) of 2%. Last but not least, the simulations found a 5% increase in continuous torque output – this could translate into higher power output for a same-size machine. Gearing up with PEEK polymers in powertrain applications In automotive, VICTREX PEEK is already frequently used in powertrain components such as seal rings, thrust washers, bushings and bearings, whereas gears in demanding powertrain applications sound a rather unlikely candidate for metal-replacement by the polymer. However, with smaller and downsized engines, NVH (noise, vibration, harshness) is, today, one of the biggest challenges for OEMs and Tier1s, and Victrex's polymer gear solutions have shown a reduction in rattle and noise issues in engine applications by up to 50% (3dB). Compared to powdered metal gears, the weight and moment of inertia is also considerably lower with VICTREX HPG™ gears, contributing to higher system efficiency. Game-changing composite solutions for aerospace At the Fakuma show Victrex will also display a variety of VICTREX™ PAEK-based composite and hybrid overmolded composite parts for use in Aerospace. The company is currently partnering with customers to meet their engineering challenges through the use of innovative solutions that offer continuous manufacturing processes and cycle times measured in minutes versus hours for thermoset alternatives. Compared to their thermoset counterparts, which are in frequent use today, thermoplastic composites are vital to drive Aerospace build rates. To build the necessary supply chain, Victrex is also investing in a joint venture, TxV Aero Composites, with long-standing development partner Tri-Mack Manufacturing. PEEK turns 40: reasons behind the success of a relatively young HPP The inert properties of the versatile PAEK polymers are one of the main reasons for its success. This family of polymers is ideally suited to extreme and demanding environments. While alternative materials can meet specific needs, PAEKs/PEEKs are located at the top of the polymer pyramid and can support multiple requirements. Their properties include light weight, high strength, and high resistance to wear, temperature, fatigue and aggressive fluids/chemicals. Together, they can contribute to enhanced fuel efficiency, extended part life, greater comfort (smooth operation, less noise), more design freedom and greater cost efficiency. The second important reason is that Victrex decided to strategically focus on this particular family of PAEK HPPs. As a result, over the last four decades, pioneering material developments, strategic decisions and close cooperation with customers set a course that arrived at, and then moved beyond, many milestones. Having achieved that progress, today Victrex continues “to shape future performance” with its PAEK/PEEK solutions, and that unwavering commitment to innovation and success is the focus and overarching motif at the company's Fakuma booth. It will also cast a first glow on PEEK's 40th anniversary in November.