CN116997481A - High voltage connector for electric vehicle - Google Patents
High voltage connector for electric vehicle Download PDFInfo
- Publication number
- CN116997481A CN116997481A CN202280021240.2A CN202280021240A CN116997481A CN 116997481 A CN116997481 A CN 116997481A CN 202280021240 A CN202280021240 A CN 202280021240A CN 116997481 A CN116997481 A CN 116997481A
- Authority
- CN
- China
- Prior art keywords
- high voltage
- voltage connector
- connector
- flame retardant
- electric vehicle
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
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Landscapes
- Compositions Of Macromolecular Compounds (AREA)
Abstract
A high voltage connector for an electric vehicle is provided. The connector includes a connector portion including an electrical pin and a protector extending from the base and surrounding at least a portion of the electrical pin. The base, the protector, or a combination thereof contains a polyamide composition comprising about 20wt.% to about 70wt.% of at least one polyamide, about 10wt.% to about 60wt.% of inorganic fibers, and about 10wt.% to about 35wt.% of a flame retardant system comprising at least one halogen-free organophosphorus compound. The polyamide composition exhibits a CTI of about 600 volts or more and a V0 rating determined according to UL94 at a thickness of 0.8 mm.
Description
Cross Reference to Related Applications
The present application claims priority from U.S. provisional patent application No. 63/162,054, having application date 2021, 3, 17, and U.S. provisional patent application No. 63/233,512, having application date 2021, 8, 16, the contents of which are incorporated herein by reference in their entirety.
Background
Electric vehicles, such as battery electric vehicles, plug-in hybrid electric vehicles, mild hybrid electric vehicles, or full hybrid electric vehicles, typically have an electric powertrain that includes an electric propulsion source (e.g., a battery) and a transmission. The propulsion source provides high voltage current to the transmission through one or more power electronics modules. Because of their small size and complex geometry, attempts have been made to form high voltage electrical connectors from polyamide compositions. Unfortunately, however, many conventional polyamide compositions, particularly those reinforced with glass fibers, lack adequate insulation properties (e.g., comparative tracking index ("CTI")) and ignition resistance. Thus, there is a need for a high voltage connector for an electric vehicle that can exhibit high CTI, yet remain flame retardant and have good mechanical properties.
Disclosure of Invention
According to one embodiment of the present invention, a high voltage connector for an electric vehicle is disclosed. The connector includes a connector portion including an electrical pin and a protector extending from the base and surrounding at least a portion of the electrical pin. The base, protector, or combination thereof contains a polyamide composition comprising about 20wt.% to about 70wt.% of at least one polyamide, about 10wt.% to about 60wt.% of inorganic fibers, and about 10wt.% to about 35wt.% of a flame retardant system comprising at least one halogen-free organophosphorus compound. The polyamide composition exhibits a comparative tracking index of about 600 volts or more at a thickness of 3mm, determined according to IEC 60112:2003, and a V0 rating determined according to UL94 at a thickness of 0.8 mm.
Other features and aspects of the invention are set forth in more detail below.
Drawings
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
FIG. 1 is a schematic diagram of one embodiment of an electric vehicle that may employ the high voltage connector of the present invention;
FIG. 2 is a perspective view of one embodiment of a high voltage connector of the present invention;
FIG. 3 is a plan view of the high voltage connector of FIG. 2 with the first connector portion and the second connector portion disengaged; and
fig. 4 is a plan view of the high voltage connector of fig. 2 with the first connector portion and the second connector portion engaged.
Detailed Description
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention.
In general, the present invention relates to high voltage connectors for Electric vehicles, such as Battery-powered Electric vehicles (Battery-Powered Electric Vehicle), fuel Cell-powered Electric vehicles (Fuel Cell-Powered Electric Vehicle), plug-in Hybrid-Electric vehicles (PHEV), mild Hybrid-Electric vehicles (MHEV), full Hybrid-Electric vehicles (FHEV), and the like. Notably, at least one component of the connector is formed from a polyamide composition comprising at least one polyamide resin in combination with inorganic fibers and a flame retardant system comprising a halogen-free organophosphorus compound. By selective control of the nature of these components and the relative concentrations of these components, the inventors have discovered that even at relatively small thickness values, such as about 4 millimeters or less, in some embodiments about 0.2 to about 3.2 millimeters, in some embodiments about 0.4 to about 2.5 millimeters, and in some embodiments about 0.8 to about 2 millimeters, the resulting polyamide composition can achieve a unique combination of insulating properties, flame retardancy, and good mechanical properties.
The insulation properties of the polyamide composition may be characterized by a high comparative tracking index ("CTI"), e.g., about 550 volts or more, in some embodiments about 580 volts or more, and in some embodiments, about 600 volts or more, as determined according to IEC 60112:2003 at part thicknesses (e.g., 3 millimeters) such as described above. The polyamide composition may also have comparable acid release resistance in a humid environment, so that corrosion may be minimized. More specifically, the pH of the deionized water phase has a pH that is relatively near neutral, such as from about 4 to about 8, in some embodiments from about 4 to about 7.5, and in some embodiments, from about 5 to about 7, 72 hours after forming the aqueous dispersion containing 70wt.% deionized water phase and 30wt.% of the polyamide composition.
The flammability of the compositions of the present invention can be characterized according to the procedure of Underwriter laboratories publication 94 (Underwriter's Laboratory Bulletin) entitled "flammability test of plastics materials, UL94 (Tests for Flammability of Plastic Materials, UL 94)". As described in more detail below, various ratings may be applied based on the fire extinguishing time (total flame time of a set of 5 samples) and the anti-drip capability. According to this procedure, for example, the composition may exhibit a V0 rating at a part thickness such as described above (e.g., about 0.4 to about 3.2 millimeters, particularly about 0.8 to about 2 millimeters, such as 0.8 millimeters), meaning that it has a total flame time of about 50 seconds or less. To achieve the V0 rating, the composition may also exhibit a total number of drops of 0 for burning particles that ignite cotton. The flame retardancy of the polyamide composition can likewise be characterized by glow wire testing. For example, during glow wire testing, the temperature at which the composition will ignite and burn for more than 5 seconds when in contact with a heated test plate can be measured. This temperature is called glow wire ignition temperature (Glow Wire Ignition Temperature, "GWIT") and is determined according to IEC-60695-2-13:2010 at a part thickness such as described above. For example, at a thickness of about 0.8 to about 2mm (e.g., 0.8 mm), the polyamide composition of the present invention may exhibit a GWIT of about 650 ℃ or more, in some embodiments about 700 ℃ or more, in some embodiments about 750 ℃ to about 900 ℃, and in some embodiments about 800 ℃ to about 875 ℃. In glow wire testing according to IEC-60695-2-12:2010 at part thicknesses such as described above, the flame retardancy of the composition can also be characterized as the highest temperature at which the material does not ignite or self-extinguish within 30 seconds after removal of the heating element. This temperature is referred to as glow wire flammability index (Glow Wire Flammability Index, "GWFI"). For example, for the polyamide composition of the present invention, the GWFI is typically about 900 ℃ or greater, in some embodiments about 920 ℃ to about 1050 ℃, and in some embodiments, about 950 ℃ to about 1000 ℃ at a thickness of about 0.8 to about 2 millimeters (e.g., 0.8 millimeters).
It is generally believed that compositions having flame retardant properties do not achieve the mechanical properties required for use in electric vehicles. However, the inventors have found that the compositions of the present invention can still achieve good impact strength, tensile properties and flexural properties. For example, the polyamide composition may exhibit a notched impact strength of about 5kJ/m for a simply supported beam measured at 23℃or-30℃according to ISO test No. 179-1:2010 (technically equivalent to ASTMD256-10, method B) 2 Or higher, in some embodiments about 6kJ/m 2 Or higher, in some embodiments about 7kJ/m 2 To about 30kJ/m 2 In some embodiments about 8kJ/m 2 To about 25kJ/m 2 . The composition may also exhibit a tensile strength of about 40 megapascals ("MPa") or greater, in some embodiments about 50MPa or greater, in some embodiments about 55 to about 200MPa, in some embodiments about 60 to about 150MPa, and a tensile modulus of about 7000MPa or greater, in some embodiments about 8000MPa or greater, in some embodiments about 9000MPa or greater, in some embodiments about 11000 to about 50000MPa, and in some embodiments about 12000 to about 25000MPa, wherein the tensile properties are determined according to ISO test No. 527:2012 (technically equivalent to ASTM D638-14 at 23 ℃), the composition may also exhibit a flexural strength of about 70 to about 500MPa, in some embodiments about 80 to about 400MPa, and in some embodiments about 90 to about 300MPa, and/or about 10000M A flexural modulus of pa to about 30000Mpa, in some embodiments about 12000Mpa to about 25000Mpa, and in some embodiments, about 14000Mpa to about 20000 Mpa. Flexural properties can be determined according to ISO test No. 178:2010 (technically equivalent to ASTM D790-10 at 23 ℃.
The high voltage connector may have a variety of different configurations depending on the particular application in which it is employed. However, the connector typically includes a first connector portion containing at least one electrical pin and a protector extending from the base around at least a portion of the electrical pin. The base and/or the protector may comprise the polyamide composition of the invention. For example, in certain embodiments, the wall thickness of the protector may be relatively small, such as about 4 millimeters or less, in some embodiments about 0.2 to 3.2 millimeters, in some embodiments about 0.4 to about 2.5 millimeters, and in some embodiments, about 0.8 to about 2 millimeters. As described above, the present inventors have found that even at such low thickness values, the polyamide composition can exhibit good properties. The first connector portion may be configured to mate with an opposing second connector portion that includes a receptacle for receiving an electrical pin. In such an embodiment, the second connector portion may include a guard extending from the base and surrounding at least a portion of the receptacle, and at least one receptacle configured to receive an electrical pin of the first connector portion. The base and/or the protector of the second connector part may also contain the polyamide composition of the invention. For example, in certain implementations, the thickness of the protector of the second connector portion may be within the ranges described above, and thus advantageously formed from a polyamide composition.
Referring to fig. 2-4, one embodiment of a high voltage connector 200 for an electric vehicle is shown. Connector 200 includes a first connector portion 202 and a second connector portion 204. The first connector portion 202 may include one or more electrical pins 206 and the second connector portion 204 may include one or more receptacles 208 for receiving the electrical pins 206. The first guard 212 may extend from the base 203 of the first connection portion 202 to surround the pins 206, and similarly, the second guard 218 may extend from the base 201 of the second connection portion 204 to surround the sockets 208. In some cases, the outer periphery of the first guard 212 may extend beyond the ends of the electrical pins 203 and the outer periphery of the second guard 218 may extend beyond the ends of the receptacle 208. As described above, the base 203 and/or the first protective member 212 of the first connector portion 202 and the base 201 and/or the second protective member 218 of the second connector portion 204 may be formed of the polyamide composition of the present invention. These parts can be formed from the polyamide composition using a variety of different techniques. Suitable techniques may include, for example, injection molding, low pressure injection molding, extrusion compression molding, gas injection molding, foam injection molding, low pressure gas injection molding, low pressure foam injection molding, gas extrusion compression molding, foam extrusion compression molding, extrusion molding, foam extrusion molding, compression molding, foam compression molding, gas compression molding, and the like. For example, an injection molding system may be employed that includes a mold into which the polyamide composition may be injected. The time inside the syringe can be controlled and optimized so that the polymer matrix is not pre-cured. When the cycle time is reached and the cartridge is full to be ejected, a piston may be used to inject the composition into the mold cavity. Compression molding systems may also be employed. Like injection molding, molding the polyamide composition into the desired article is also performed in a mold. The composition may be placed into the compression mold using any known technique, such as by automated robotic arm pick-up. The temperature of the mold may be maintained at or above the curing temperature of the polymer matrix for a desired period of time to allow curing. The molded product may then be cured by bringing it to a temperature below the melting temperature. The resulting product may be demolded. The cycle time of each molding process can be adjusted to fit the polymer matrix to achieve sufficient bonding and to increase overall process yield.
Although not required, the first connector portion 202 may also include an identification mark 210 secured to or defined by the first protector 212. The second connection portion 204 may also optionally define an alignment window 220 sized according to the identification mark 210 to more easily determine when the portions are fully mated. For example, the identification mark 210 may not be readable unless the barrier 221 covers a portion of the identification mark 210. Optionally, the second connection portion 204 may include supplemental indicia 224 located near the alignment window 220.
Various embodiments of the present invention will now be described in more detail.
I.Polyamide composition
A.Polyamide
Typically, the polyamide constitutes from about 20wt.% to about 70wt.%, in some embodiments from about 30wt.% to about 60wt.%, and in some embodiments, from about 35wt.% to about 55wt.% of the composition. Polyamides generally have CO-NH bonds in the main chain and are obtained by condensation of diamines and dicarboxylic acids, ring-opening polymerization of lactams or self-condensation of aminocarboxylic acids. For example, the polyamide may contain aliphatic repeat units derived from aliphatic diamines typically having 4 to 14 carbon atoms. Examples of such diamines include: linear aliphatic alkylene diamines such as 1, 4-tetramethylene ethylenediamine, 1, 6-hexamethylenediamine, 1, 7-heptanediamine, 1, 8-octanediamine, 1, 9-nonanediamine, 1, 10-decanediamine, 1, 11-undecanediamine, 1, 12-dodecanediamine, etc.; branched aliphatic alkylene diamines such as 2-methyl-1, 5-pentanediamine, 3-methyl-1, 5-pentanediamine, 2, 4-trimethyl-1, 6-hexanediamine, 2, 4-dimethyl-1, 6-hexanediamine, 2-methyl-1, 8-octanediamine, 5-methyl-1, 9-nonanediamine, and the like; and combinations thereof. Of course, aromatic and/or cycloaliphatic diamines may also be employed. Further, examples of the dicarboxylic acid component may include aromatic dicarboxylic acids (e.g., terephthalic acid, isophthalic acid, 2, 6-naphthalene dicarboxylic acid, 2, 7-naphthalene dicarboxylic acid, 1, 4-benzene dioxy-diacetic acid, 1, 3-benzene dioxy-diacetic acid, biphenyl dicarboxylic acid, 4 '-oxydibenzoic acid, diphenylmethane-4, 4' -dicarboxylic acid, diphenyl sulfone-4, 4 '-dicarboxylic acid, 4' -biphenyl dicarboxylic acid, etc.), aliphatic dicarboxylic acids (e.g., adipic acid, sebacic acid, etc.), and the like. Examples of lactams include pyrrolidone, aminocaproic acid, caprolactam, undecyllactam, lauryllactam, and the like. Also, examples of the aminocarboxylic acid include amino fatty acids, which are the above-mentioned lactam compounds that have been ring-opened by water.
In certain embodiments, "aliphatic" polyamides formed solely from aliphatic monomer units (e.g., diamine and dicarboxylic acid monomer units) are employed. Specific examples of such aliphatic polyamides include, for example, nylon-4 (poly-alpha-pyrrolidone), nylon-6 (polycaprolactone), nylon-11 (polyundecylamide), nylon-12 (polydodecamide), nylon-46 (polytetramethylene adipamide), nylon-66 (polyhexamethylene adipamide), nylon-610, and nylon-612. Nylon-6 and nylon-66 are particularly suitable. In one embodiment, for example, nylon-6 or nylon-66 may be used alone. In other embodiments, a blend of nylon-6 and nylon-66 may be employed. When such a blend is employed, the weight ratio of nylon-66 to nylon-6 is typically from 1 to about 2, in some embodiments from about 1.1 to about 1.8, and in some embodiments, from about 1.2 to about 1.6.
Of course, aromatic monomer units may also be included in the polyamide, such that it is considered semi-aromatic (including both aliphatic and aromatic monomer units) or fully aromatic (including only aromatic monomer units). For example, suitable semi-aromatic polyamides may include: poly (nonylene terephthalamide) (PA 9T), poly (nonylene terephthalamide/nonylene decane diamide) (PA 9T/910), poly (nonylene terephthalamide/nonylene dodecane diamide) (PA 9T/912), poly (nonylene terephthalamide/11-aminoundecane amide) (PA 9T/11), poly (nonylene terephthalamide/12-aminoundecane amide) (PA 9T/12), poly (decylene terephthalamide/11-aminoundecane amide) (PA 10T/11), poly (decylene terephthalamide/12-aminoundecane amide) (PA 10T/12), poly (decylene terephthalamide/12-aminododecane amide) (PA 10T/10), poly (decylene terephthalamide/decylene dodecane diamide) (PA 10T/1010), poly (decylene terephthalamide/decylene terephthalamide) (PA 10T/1012), poly (decylene terephthalamide/butylhexanediamide) (PA 10T/46), poly (p-xylylene terephthalamide/10T/1212), poly (p-dodecylene terephthalamide) (PA/66), poly (p-dodecylene terephthalamide) and poly (p-dodecylene terephthalamide) (PA/66) Poly (dodecyleneterephthalamide/caprolactam) (PA 12T/6), poly (dodecyleneterephthalamide/hexylenehexanediamide) (PA 12T/66), and the like.
The polyamides used in polyamide compositions are generally crystalline or semi-crystalline in nature and thus have a measurable melting temperature. The melting temperature may be relatively high so that the composition may provide a substantial degree of heat resistance to the resulting part. For example, the polyamide may have a melting temperature of about 220 ℃ or greater, in some embodiments from about 240 ℃ to about 325 ℃, and in some embodiments, from about 250 ℃ to about 335 ℃. The polyamide may also have a relatively high glass transition temperature, for example, about 30 ℃ or greater, in some embodiments about 40 ℃ or greater, and in some embodiments, about 45 ℃ to about 140 ℃. It is known in the art that the glass transition temperature and melting temperature can be determined using differential scanning calorimetry ("DSC"), for example by ISO test 11357-2:2013 (glass transition temperature) and 2-3:2011 (melting temperature).
B.Inorganic fiber
The inorganic fibers generally constitute from about 10wt.% to about 60wt.% of the composition, in some embodiments from about 15wt.% to about 55wt.% of the composition, and in some embodiments, from about 20wt.% to about 50wt.% of the composition. Inorganic fibers generally have a high degree of tensile strength relative to their mass. For example, the ultimate tensile strength of the fibers is typically from about 1000 to about 15000MPa, in some embodiments from about 2000MPa to about 10000MPa, and in some embodiments, from about 3000MPa to about 6000MPa. The high strength fibers may be formed from materials that also have electrical insulating properties, such as glass, ceramic (e.g., alumina or silica), and the like, as well as mixtures thereof. Glass fibers are particularly suitable, for example E-glass, A-glass, C-glass, D-glass, AR-glass, R-glass, S1-glass, S2-glass, and the like, and mixtures thereof. The inorganic fibers may have a relatively small median diameter, such as about 50 microns or less, in some embodiments about 0.1 to about 40 microns, and in some embodiments about 2 to about 20 microns, as determined, for example, using laser diffraction techniques according to ISO 13320:2009 (e.g., using a Horiba LA-960 particle size distribution analyzer). It is believed that the small diameter of such fibers may allow their length to be more easily reduced during melt blending, further improving surface appearance and mechanical properties. For example, after formation of the polymer composition, the average length of the inorganic fibers may be relatively small, such as from about 10 to about 800 microns, in some embodiments from about 100 to about 700 microns, and in some embodiments, from about 200 to about 600 microns. The inorganic fibers may also have a relatively high aspect ratio (average length divided by nominal diameter), such as from about 1 to about 100, in some embodiments from about 10 to about 60, and in some embodiments, from about 30 to about 50.
C.Flame retardant systems
In addition to the above components, the polyamide composition also contains a flame retardant system that can achieve the desired flame retardant, insulating, and mechanical properties without the use of conventional halogen-based flame retardants. The flame retardant system generally comprises from about 10wt.% to about 35wt.% of the polyamide composition, in some embodiments from about 12wt.% to about 30wt.% of the polyamide composition, and in some embodiments, from about 15wt.% to about 25wt.% of the polyamide composition. The flame retardant system generally comprises at least one halogen-free flame retardant. The halogen (e.g., bromine, chlorine, and/or fluorine) content of such flame retardants is typically about 1500ppm (parts per million) by weight or less, in some embodiments about 900ppm or less, and in some embodiments about 50ppm or less. In certain embodiments, the flame retardant is completely halogen-free (i.e., 0 ppm). The particular nature of the halogen-free flame retardant is selected to help achieve the desired flammability performance without adversely affecting the mechanical properties of the composition.
In this regard, the flame retardant system includes one or more halogen-free organophosphorus flame retardants in an amount generally from about 20wt.% to 100wt.%, in some embodiments from about 30wt.% to 100wt.%, and in some embodiments, from about 40wt.% to about 80wt.% of the flame retardant system. One particularly suitable organophosphorus flame retardant is phosphinate, which can enhance the flame retardant properties of the overall composition, especially for relatively thin parts, without adversely affecting mechanical and insulating properties. Such phosphinates are generally salts of phosphinic acid and/or salts of diphosphinic acid, for example those of the general formula (I) and/or of the general formula (II):
Wherein, the liquid crystal display device comprises a liquid crystal display device,
R 7 and R is 8 Independently hydrogen or a substituted or unsubstituted straight, branched or cyclic hydrocarbon group having 1 to 6 carbon atoms (e.g., alkyl, alkenyl, alkynyl, aralkyl, aryl, alkaryl, etc.), particularly an alkyl group having 1 to 4 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, or tert-butyl;
R 9 is a substituted or unsubstituted straight, branched or cyclic C 1 -C 10 An alkylene group, an arylene group, an arylalkylene group, or an alkylarylene group, such as a methylene group, an ethylene group, a n-propylene group, an isopropylene group, a n-butylene group, a tert-butylene group, a n-pentylene group, a n-octylene group, a n-dodecylene group, a phenylene group, a naphthylene group, a methylphenyl group, an ethylphenylene group, a tert-butylphenylene group, a methylnaphthylene group, an ethylnaphthylene group, a tert-butylnaphthylene group, a phenylethylene group, a phenylpropylene group, or a phenylbutylene group;
z is Mg, ca, al, sb, sn, ge, ti, zn, fe, zr, ce, bi, sr, mn, li, na, K and/or protonated nitrogen group;
y is 1 to 4, preferably 1 to 2 (e.g. 1);
n is 1 to 4, preferably 1 to 2 (e.g. 1); and
m is 1 to 4, preferably 1 to 2 (e.g. 2).
The phosphinates may be prepared using any known technique, for example by reacting the phosphinic acid with a metal carbonate, metal hydroxide or metal oxide in aqueous solution. Particularly suitable phosphinates include, for example, dimethylphosphinic acid, ethylmethylphosphinic acid, diethylphosphinic acid, methyl-n-propylphosphinic acid, methane-bis (methylphosphinic acid), ethane-1, 2-bis (methylphosphinic acid), hexane-1, 6-bis (methylphosphinic acid), benzene-1, 4-bis (methylphosphinic acid), toluene Metal salts of phosphinic acid, diphenylphosphinic acid, hypophosphorous acid, and the like. The resulting salt is typically a monomeric compound; however, polymerized phosphinates may also be formed. Particularly suitable metals for the salt may include Al and Zn. For example, one particularly suitable phosphinate is zinc diethylphosphinate, such as is available from Clariant, craienOP 950 is commercially available. Another particularly suitable phosphinate is aluminum diethylphosphinate, for example from Craien under the name +.>OP 1230 is commercially available.
Of course, other suitable organophosphorus flame retardants may also be employed in the polyamide composition. Examples of such flame retardants may include, for example, salts of phosphoric acid, such as phosphates, phosphonites, phosphites, phosphonites, and the like; phosphazenes; etc., and combinations thereof. The cation used to form the salt of phosphoric acid may be a metal, such as Mg, ca, al, sb, sn, ge, ti, zn, fe, zr, ce, bi, sr, mn, li, na or K, and/or a protonated nitrogen group. Aluminum and zinc are particularly suitable when metal cations are employed, such as aluminum phosphite, zinc phosphite, aluminum phosphonate, zinc phosphonate, and the like. Suitable protonated nitrogen groups can similarly include those with a substituted or unsubstituted ring structure with at least one nitrogen heteroatom (e.g., heterocycle or heteroaryl) in the ring structure and/or at least one nitrogen-containing functional group substituted at a carbon atom and/or heteroatom of the ring structure (e.g., amino, acylamino, etc.). Examples of such heterocyclic groups may include, for example, pyrrolidine, imidazoline, pyrazolidine, oxazolidine, isoxazolidine, thiazolidine, isothiazolidine, piperidine, piperazine, thiomorpholine, and the like. Likewise, examples of heteroaryl groups may include, for example, pyrrole, imidazole, pyrazole, oxazole, isoxazole, thiazole, isothiazole, triazole, furazan, oxadiazole, tetrazole, pyridine, diazine, oxazine, triazine, tetrazine, and the like. The ring structure of the group may also be substituted with one or more functional groups, such as acyl, acyloxy, acylamino, alkoxy, alkenyl, alkyl, amino, aryl, aryloxy, carboxyl ester, cycloalkyl, hydroxyl, halogen, haloalkyl, heteroaryl, heterocyclyl, and the like, if desired. Substitution may occur on heteroatoms and/or carbon atoms of the ring structure.
One suitable nitrogen group is melamine, which contains a 1,3, 5-triazine ring structure, which 1,3, 5-triazine ring structure is substituted on each of the three carbon atoms with an amino functional group. Examples of suitable melamine phosphates may include, for example, melamine orthophosphates, melamine pyrophosphates, melamine polyphosphates, and the like. For example, melamine polyphosphate may be known from BASF under the name BASF(e.g.)>200 or 200/70). Another suitable nitrogen group is piperazine, which is a six-membered ring structure containing two nitrogen atoms in the opposite positions of the ring. Suitable piperazine phosphates may include, for example, piperazine orthophosphate, piperazine pyrophosphate, piperazine polyphosphate, and the like. In certain embodiments, a mixture of melamine phosphate and piperazine phosphate may be employed in the flame retardant system.
Of course, other organophosphorus flame retardants may also be used in the flame retardant system. For example, in one embodiment, monomeric and oligomeric phosphates and phosphonates may be employed, such as tributyl phosphate, triphenyl phosphate, tricresyl phosphate, diphenyl cresyl phosphate, diphenyl octyl phosphate, diphenyl 2-ethyltolyl phosphate, tri (isopropylphenyl) phosphate, resorcinol bridged oligomeric phosphate, bisphenol a phosphate (e.g., bisphenol a bridged oligomeric phosphate or bisphenol a bis (diphenyl phosphate)), and the like, as well as mixtures thereof. Aryl phosphates, aryl phosphonites, phosphinates, red phosphorus, and the like may also be used as suitable organophosphorus flame retardants.
In certain embodiments, the flame retardant system may be formed entirely from one type of organophosphorus flame retardant, such as a phosphinate. However, in other cases, it may be desirable to employ a combination of two or more types of organophosphorus flame retardants to achieve the desired properties. For example, in one embodiment, the phosphinate may constitute from about 50wt.% to about 95wt.%, in some embodiments from about 60wt.% to about 92wt.%, in some embodiments from about 70wt.% to about 90wt.%, and also from about 5wt.% to about 25wt.%, in some embodiments from about 9wt.% to about 22wt.%, in some embodiments from about 10wt.% to about 20wt.%, and in some embodiments, from about 11wt.% to about 18wt.% of the entire polyamide composition. Likewise, other types of organophosphorus flame retardants, such as salts of phosphoric acid (e.g., aluminum phosphite, aluminum phosphonate, melamine polyphosphate, etc.), may constitute from about 5wt.% to about 50wt.%, in some embodiments from about 8wt.% to about 40wt.%, and in some embodiments, from about 10wt.% to about 30wt.% of the flame retardant system.
The flame retardant system may also be formed entirely of an organophosphorus flame retardant, such as the flame retardants described above. However, in certain embodiments, it may be desirable to use additional compounds to help increase the effectiveness of the system. For example, inorganic compounds may be used as low halogen char-forming agents and/or smoke suppressants in combination with the organophosphorus compounds. Suitable inorganic compounds (anhydrous or hydrated) may include inorganic molybdates such as zinc molybdate (e.g., under the trade name Huber Engineered Materials) Commercially available), calcium molybdate, ammonium octamolybdate, zinc molybdate-magnesium silicate, and the like. Other suitable inorganic compounds may include inorganic borates such as zinc borate (available under the trade name +.>Purchased), and the like; zinc phosphate, zinc hydrogen phosphate, zinc pyrophosphate, zinc basic chromium (VI) acid (zinc yellow), zinc chromate, zinc permanganate, silica, magnesium silicate, calcium carbonate, titanium dioxide, magnesium hydroxide, and the like. In particular embodiments, it may be desirable to use inorganic zinc compounds, such as zinc molybdate, boronZinc acid, etc., to improve the overall performance of the composition. When used, such inorganic compounds (e.g., zinc borate) may constitute, for example, from about 1wt.% to about 20wt.%, in some embodiments from about 2wt.% to about 15wt.%, and in some embodiments, from about 3wt.% to about 10wt.%, and also from about 0.1wt.% to about 10wt.%, in some embodiments, from about 0.2wt.% to about 5wt.%, and in some embodiments, from about 0.5wt.% to about 4wt.% of the entire polyamide composition.
Other additives may also be used in the flame retardant system of the present invention if desired. For example, nitrogen-containing synergists may be employed that act with the organophosphorus compounds and/or other components to produce a more effective flame retardant system. Such nitrogen-containing synergists may include nitrogen-containing synergists of formulae (III) to (VIII) or mixtures thereof:
Wherein, the liquid crystal display device comprises a liquid crystal display device,
R 5 、R 6 、R 7 、R 9 、R 10 、R 11 、R 12 and R is 13 Independently is: hydrogen; c (C) 1 -C 8 An alkyl group; c (C) 5 -C 16 Cycloalkyl or alkylcycloalkyl, optionally substituted with hydroxy or C 1 -C 4 Hydroxyalkyl substitution; c (C) 2 -C 8 Alkenyl groups; c (C) 1 -C 8 Alkoxy, acyl or acyloxy; c (C) 6 -C 12 -aryl or arylalkyl; OR (OR) 8 Or N (R) 8 )R 9 Wherein R is 8 Is hydrogen, C 1 -C 8 Alkyl, C 5 -C 16 Cycloalkyl or alkylcycloalkyl, optionally substituted with hydroxy or C 1 -C 4 Hydroxyalkyl, C 2 -C 8 Alkenyl, C 1 -C 8 Alkoxy, acyl or acyloxy or C 6 -C 12 Aryl or arylalkyl substitution;
m is 1 to 4;
n is 1 to 4;
x is a compound capable of reacting with formula IIThe triazine compounds of I form the acid of the adduct. For example, the nitrogen-containing potentiating agents may include benzoguanamine, tris (hydroxyethyl) isocyanurate, allantoin, glycoluril, melamine cyanurate, dicyandiamide, guanidine, and the like. Examples of such synergists areJenewein et alU.S. Pat. No. 6,365,071,Hoerold et alU.S. Pat. No. 7,255,814,Bauer et alIs described in us patent No. 7,259,200. One particularly suitable synergist is melamine cyanurate, e.g. from basf under the nameMC (e.g.)>MC 15, MC25, MC 50).
For example, when employed, the nitrogen-containing synergist may constitute from about 0.5wt.% to about 30wt.%, in some embodiments from about 1wt.% to about 25wt.%, and in some embodiments, from about 2wt.% to about 20wt.%, and also constitute from about 0.1wt.% to about 10wt.%, in some embodiments, from about 0.5wt.% to about 8wt.%, and in some embodiments, from about 1wt.% to about 6wt.% of the entire polyamide composition.
The flame retardant system and/or the polyamide composition itself typically has a relatively low level of halogen (i.e., bromine, fluorine, and/or chlorine), for example, about 15000ppm or less, in some embodiments about 5000ppm or less, in some embodiments about 1000ppm or less, in some embodiments about 800ppm or less, and in some embodiments, about 1ppm to about 600ppm. However, in certain embodiments of the present invention, halogen-based flame retardants may still be used as an optional component. Particularly suitable halogen-based flame retardants are fluoropolymers such as Polytetrafluoroethylene (PTFE), fluorinated Ethylene Polypropylene (FEP) copolymers, perfluoroalkoxy (PFA) resins, polychlorotrifluoroethylene (PCTFE) copolymers, ethylene-chlorotrifluoroethylene (ECTFE) copolymers, ethylene-tetrafluoroethylene (ETFE) copolymers, polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), copolymers and blends thereof, and other combinations. When used, such halogen-based flame retardants typically constitute only about 10wt.% or less, in some embodiments about 5wt.% or less, and in some embodiments about 1wt.% or less of the flame retardant system. Also, halogen-based flame retardants typically constitute about 5wt.% or less, in some embodiments about 1wt.% or less, and in some embodiments about 0.5wt.% or less of the entire polyamide composition.
D.Other components
Various other additives may also be included in the polyamide composition, such as impact modifiers, compatibilizers, particulate fillers (e.g., mineral fillers), lubricants, pigments, antioxidants, light stabilizers, heat stabilizers, slip additives, and/or other materials for improving performance and processability. In certain embodiments, for example, the composition may contain a UV stabilizer. Suitable UV stabilizers may include, for example, benzophenones, benzotriazoles (e.g., 2- (2-hydroxy-3, 5-di-alpha-cumylphenyl) -2H-benzotriazole @, for example234 2- (2-hydroxy-5-tert-octylphenyl) -2H-benzotriazole (/ -)>329 2- (2-hydroxy-3-alpha-cumyl-5-tert-octylphenyl) -2H-benzotriazole (+)>928 (2, 4-diphenyl-6- (2-hydroxy-4-hexyloxyphenyl) -s-triazine (-/-), etc.)>1577 A) sterically hindered amine (e.g. bis (2, 6-tetramethyl-4-piperidinyl) sebacate (-)>770 Dimethyl succinate and 1- (2-hydroxyethyl) -4-hydroxy-2, 6-tetramethyl-4-piperidine (>622 Polymers) and the like, as well as mixtures thereof. When used, such UV stabilizers generally constitute from about 0.05wt.% to about 2wt.%, in some embodiments from about 0.1wt.% to about 1.5wt.%, and in some embodiments, from about 0.2wt.% to about 1.0wt.% of the composition.
II.Formation of
The polyamide, inorganic fibers, flame retardant system and other optional additives may be melt processed or blended together. The components may be supplied individually or in combination to an extruder that includes at least one screw rotatably mounted and housed within a barrel (e.g., a cylindrical barrel), and the extruder may define a feed section along the length of the screw and a melt section positioned downstream of the feed section. The fibers may optionally be added to a location downstream of the polyamide supply point (e.g., a hopper). Flame retardants may also be added to the extruder at a location downstream of the polyamide feed point, if desired. One or more sections of the extruder are typically heated to form the composition at a temperature in the range of, for example, from about 200 ℃ to about 450 ℃, in some embodiments from about 220 ℃ to about 350 ℃, in some embodiments from about 250 ℃ to about 350 ℃. The speed of the screw may be selected to achieve the desired residence time, shear rate, melt processing temperature, etc. For example, the screw speed may be in the range of about 50 revolutions per minute to about 800 revolutions per minute ("rpm"), in some embodiments about 70rpm to about 150rpm, and in some embodiments, about 80rpm to about 120 rpm. Apparent shear rates during melt blending may also be in the range of about 100s -1 Up to about 10000s -1 In some embodiments about 500s -1 Up to about 5000s -1 And in some embodiments about 800s -1 Up to about 1200s -1 Within a range of (2). Apparent shear rate is equal to 4Q/pi R 3 Where Q is the volumetric flow rate of the polymer melt ("m 3 S ") and R is the radius (" m ") of the capillary (e.g., extruder die) through which the molten polymer flows.
Regardless of the particular manner in which it is formed, the resulting polymer composition may have excellent thermal properties. For example, the melt viscosity of the polyamide composition may be low enough toSo that it can easily flow into the cavity of a mold having a small size. In a particular embodiment, the polyamide composition is present at 1000 seconds -1 The melt viscosity may be determined at a shear rate of about 400 to about 1,000 Pascal-seconds ("Pa-s"), in some embodiments about 450 to about 900Pa-s, and in some embodiments, about 500 to about 800Pa-s. Melt viscosity can be determined according to ISO test No. 11443:2005 at a temperature 15 ℃ above the melting temperature of the composition (e.g., 285 ℃).
III.Electric vehicle
As described above, the high-voltage electrical connector is configured for an electric vehicle. For example, connectors may be used in power systems to achieve a variety of different objectives. For example, the high voltage connector may electrically connect a propulsion source (e.g., battery, fuel cell, etc.) to the power electronics module and/or electrically connect the power electronics module to certain motors and/or transmissions. For example, referring to FIG. 1, one embodiment of an electric vehicle 12 that includes a powertrain 10 is illustrated. The powertrain 10 includes one or more electric motors 14, the electric motors 14 being coupled to a transmission 16, the transmission 16 in turn being mechanically coupled to a drive shaft 20 and wheels 22. Although not required, in this particular embodiment, the transmission 16 is also connected to the engine 18. The electric machine 14 may be capable of operating as a motor or a generator to provide propulsion and retarding capabilities. The power system 10 also includes a propulsion source, such as a battery pack 24, that stores and provides energy for use by the electric machine 14. The battery pack 24 typically provides a high voltage current output (e.g., DC current) from one or more arrays of battery cells, which may include one or more battery cells.
The power system 10 may also include at least one power electronics module 26, which power electronics module 26 is connected to the battery pack 24 and may include a power converter (e.g., an inverter, a rectifier, a voltage converter, etc., and combinations thereof). The power electronics module 26 is typically electrically connected to the electric machine 14 and provides the ability to transfer electrical energy bi-directionally between the battery pack 24 and the electric machine 14. For example, the battery pack 24 may provide a DC voltage, while the motor 14 may require a three-phase AC voltage to operate. The power electronics module 26 may convert the DC voltage to a three-phase AC voltage based on the requirements of the electric machine 14. In the regeneration mode, the power electronics module 26 may convert the three-phase AC voltage from the electric machine 14 acting as a generator to the DC voltage required by the battery pack 24. The description herein applies equally to a purely electric vehicle. The battery pack 24 may also provide energy for other vehicle electrical systems. For example, the powertrain system may employ a DC/DC converter module 28, which module 28 converts the high voltage DC output from the battery pack 24 to a low voltage DC power source compatible with other vehicle loads, such as compressors and electric heaters. In a typical vehicle, the low voltage system is electrically connected to an auxiliary battery 30 (e.g., a 12V battery). There may also be a battery energy control module (Battery Energy Control Module, BECM) 33 in communication with the battery pack 24, which acts as a controller for the battery pack 24, and may include an electronic monitoring system that manages the temperature and state of charge of each battery cell. The battery pack 24 may also have a temperature sensor 31, such as a thermistor or other thermometer. The temperature sensor 31 may communicate with the BECM 33 to provide temperature data about the battery pack 24. The temperature sensor 31 may also be located on or near a battery cell within the power cell 24. It is also contemplated that more than one temperature sensor 31 may be used to monitor the temperature of the battery cells.
In certain embodiments, the battery pack 24 may be recharged by an external power source 36, such as a power outlet. The external power source 36 may be electrically connected to an electric vehicle supply equipment (Electric Vehicle Supply Equipment, EVSE) that regulates and manages the transfer of electrical energy between the power source 36 and the vehicle 12. The EVSE 38 may have a charging connector 40 for insertion into the charging port 34 of the vehicle 12. The charging port 34 may be any type of port configured to transfer power from the EVSE 38 to the vehicle 12 and may be electrically connected to a charger or an on-board power conversion module 32. The power conversion module 32 may regulate the power supplied from the EVSE 38 to provide the appropriate voltage and current levels to the battery pack 24. The power conversion module 32 may interface with the EVSE 38 to coordinate the delivery of power to the vehicle 12.
As known to those skilled in the art, the high voltage connector of the present invention may be used in a powertrain of an electric vehicle to achieve a variety of different objectives. Referring again to fig. 1, for example, a high voltage connector (not shown) may electrically connect the battery pack 24 to power electronics modules, such as the power electronics module 26, the DC/DC converter module 28, and/or the power conversion module 32. The high voltage connector (not shown) may also electrically connect a power electronics module (e.g., module 32) to certain of the electric machines 14 and/or electrically connect the power electronics module and/or the electric machines 14 to the transmission 16. Of course, the high voltage connector may be used in conjunction with other parts of an electric vehicle in addition to being used in a powertrain. For example, in one embodiment, the high voltage connector may be used in an electric vehicle power supply device, such as the charging connector 40 shown in fig. 1.
The invention will be better understood with reference to the following examples.
Test method
Tensile modulus, tensile stress, and tensile elongation at break: tensile properties may be tested according to ISO test No. 527:2012 (technically equivalent to ASTM D638-14). Modulus and strength measurements can be made on the same test strip sample 80mm in length, 10mm in thickness and 4mm in width. The test temperature may be 23℃and the test speed may be 1 or 5mm/min.
Flexural modulus and flexural stress: flexural properties can be tested according to ISO test No. 178:2010 (technically equivalent to ASTM D790-10). The test can be performed on a 64mm support span. Testing can be performed on the center portion of an uncut ISO 3167 multipurpose stick. The test temperature may be 23℃and the test speed may be 2mm/min.
Impact strength of the unnotched simply supported beam: the unnotched simply supported beam performance can be tested according to ISO test ISO 179-1:2010 (technically equivalent to ASTM D256-10, method B). The test can be performed using type 1 specimen dimensions (80 mm length, 10mm width and 4mm thickness). A single tooth milling machine may be used to cut the sample from the center of the multi-purpose bar. The test temperature may be 23 ℃.
Notched simply supported beam impact strength: notched simply supported beam performance may be tested according to ISO test ISO 179-1:2010 (technically equivalent to ASTM D256-10, method B). The test can be performed using type a notches (0.25 mm base radius) and type 1 specimen dimensions (80 mm length, 10mm width and 4mm thickness). A single tooth milling machine may be used to cut the sample from the center of the multi-purpose bar. The test temperature may be 23℃or-30 ℃.
Comparative tracking index ("CTI"): the Comparative Tracking Index (CTI) may be determined according to international standard IEC 60112-2003 to provide a quantitative indication of the ability of the composition to function as an electrical insulation material under humid and/or contaminated conditions. In determining the CTI rating of the composition, two electrodes were placed on molded test specimens. When a 0.1% aqueous ammonium chloride solution was dropped onto the test specimen, a voltage difference was established between the electrodes. The maximum voltage at which five samples were subjected to 50 drops without failure was determined. The test voltage ranges from 100 to 600 volts with an increment of 25V. The voltage value causing the failure when fifty drops of the electrolyte was used was "comparative tracking index". This value indicates the relative tracking resistance of the material. According to UL746A, a nominal part thickness of 3mm is considered to represent performance at other thicknesses.
pH test: after contact with the sample, a test is performed to determine the pH of the aqueous phase of the aqueous dispersion. First, the pH of deionized water was determined as a reference. Then, a 3 gram sample of the particles was placed in 7 grams deionized water (70 wt.% deionized water phase, 30wt.% particles as the dispersed phase) in a sealed vessel to form an aqueous dispersion. The containers were stored in an oven at a temperature below 70 ℃ for 72 hours. Thereafter, the pH of the aqueous phase was determined.
UL94: the sample is supported in an upright position and a flame is applied to the bottom of the sample. The flame was applied for ten seconds and then removed until the combustion stopped, at which point the flame was applied again for ten seconds and then removed. Two sets of five samples were tested. The sample size was 125mm long, 13mm wide and 0.8mm thick. Both groups were conditioned before and after aging. For the unaged test, each thickness was tested after conditioning at 23 ℃ and 50% relative humidity for 48 hours. For the aging test, five samples of each thickness were tested after conditioning at 70 ℃ for 7 days.
Examples1-4
Four different polyamide resin samples were formed from the components listed in the following table for use in forming high voltage connectors for electric vehicles.
1 Containing about 80wt.% aluminum phosphinate and 20wt.% halogen-free synergistic flame retardant.
Once formed, the resulting composition is injection molded at a temperature of about 280 ℃ and a tool temperature of 80 ℃ to 90 ℃. The injection molded samples of example 3 were tested for various properties as described above. The results are shown below.
Ex.3 | |
UL94 0.4mm | V0 |
UL94 0.8mm | V0 |
CTI(3.0mm) | 600V |
Examples 5 to 12
Eight different polyamide resin samples were formed from the components listed in the following table for use in forming high voltage connectors for electric vehicles. Samples were formed using a co-rotating twin screw extruder (ZSK 40 of colupulone (Coperion)) with a standard screw design. The extruder was equipped with a "weight loss" multiple feed system, optionally with the addition of components from the main hopper and downstream. The barrel and die temperatures are between 270 ℃ and 290 ℃, the melt temperature is below 300 ℃, and the throughput is in the range of 80-120 kg per hour. The components of each formulation are described in more detail below.
Once formed, the resulting composition is injection molded at a temperature of about 280 ℃ and a tool temperature of 80 ℃ to 90 ℃.
The injection molded samples of examples 5-11 were tested for various properties as described above.
Ex.5 | Ex.6 | Ex.7 | Ex.8 | Ex.9 | Ex.10 | Ex.11 | |
UL94 0.4mm | V0/V2 | V0/V2 | V0/V2 | V0/V2 | V0 | V0 | V0 |
UL94 0.8mm | V0 | V0 | V0 | V2 | V0 | V0 | V0 |
UL94 1.6mm | V0 | V0 | V0 | V0 | V0 | V0 | V0 |
CTI(3.0mm) | 600 | 600 | 600 | - | 600 | 600 | 600 |
Ex.5 | Ex.6 | Ex.7 | Ex.8 | Ex.9 | Ex.10 | Ex.11 | |
Compressive yield strength (MPa) | 130.5 | 145.1 | 140.0 | 139.1 | 143.2 | 144.0 | 140 |
Elongation at break (%) | 3.5 | 2.9 | 3.0 | 3.0 | 2.9 | 2.7 | 2.9 |
Tensile modulus (MPa) | 9,000 | 10,400 | 10,000 | 8,800 | 10,800 | 10,400 | 9,200 |
Simply supported beam notch at 23 ℃ (kJ/m) 2 ) | 9.0 | 10.5 | 11.5 | 7.8 | 10.1 | 13.7 | 8.5 |
Simply supported beam notch (kJ/m) at-30 DEG C 2 ) | 7.5 | 9.5 | - | 6.6 | 9.3 | 11.0 | 7.5 |
Corrosion at 300 ℃ (mg) | 5.1 | 7.6 | 5.5 | 4.3 | 5.4 | 3.0 | - |
PH test | 4.3 | 4.3 | 4.4 | - | - | - | 5.5 |
These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.
Claim (modification according to treaty 19)
1. A high voltage connector for an electric vehicle, the connector comprising a connector portion comprising an electrical pin and a protector extending from a base and surrounding at least a portion of the electrical pin, wherein the base, the protector, or a combination thereof comprises a polyamide composition comprising about 20wt.% to about 70wt.% of at least one polyamide, about 10wt.% to about 60wt.% of inorganic fibers, and about 10wt.% to about 35wt.% of a flame retardant system comprising at least one halogen-free organophosphorus compound, further wherein the polyamide composition exhibits a comparative tracking index of about 600 volts or more determined according to IEC 60112:2003 at a thickness of 3 millimeters and a V0 rating determined according to UL94 at a thickness of 0.8 mm.
2. The high voltage connector of claim 1, wherein the polyamide composition exhibits a tensile modulus of about 8500MPa or greater as determined according to ISO test No. 527-1:2019.
3. The high voltage connector of claim 1, wherein the wall thickness of the protector is about 0.8 millimeters to about 2 millimeters.
4. The high voltage connector of claim 1, wherein a periphery of the guard extends beyond an end of the electrical pin.
5. The high voltage connector of claim 1, wherein the protective member comprises a polyamide composition.
6. The high voltage connector of claim 1, wherein the connector further comprises a second connector portion comprising a receptacle for receiving the electrical pin and a protector extending from the base and surrounding at least a portion of the receptacle.
7. The high voltage connector of claim 6, wherein the base of the second connection portion, the protector of the second connection portion, or a combination thereof comprises the polyamide composition.
8. The high voltage connector of claim 1, wherein the polyamide comprises an aliphatic polyamide.
9. The high voltage connector of claim 8, wherein the polyamide composition comprises a combination of nylon-6 and nylon-6, 6.
10. The high voltage connector of claim 1, wherein the inorganic fibers comprise glass fibers.
11. The high voltage connector of claim 1, wherein the flame retardant system comprises a phosphinate salt having the general formula (I) and/or the general formula (II):
wherein, the liquid crystal display device comprises a liquid crystal display device,
R 7 and R is 8 Independently hydrogen or a substituted or unsubstituted straight, branched or cyclic hydrocarbon group having 1 to 6 carbon atoms;
R 9 is a substituted or unsubstituted straight, branched or cyclic C 1 -C 10 Alkylene, arylene, arylalkylene, or alkylarylene;
z is Mg, ca, al, sb, sn, ge, ti, zn, fe, zr, ce, bi, sr, mn, li, na, K and/or protonated nitrogen group;
y is 1 to 4;
n is 1 to 4; and
m is 1 to 4.
12. The high voltage connector of claim 1, wherein the phosphinate is a metal salt of dimethyl phosphinic acid, ethyl methyl phosphinic acid, diethyl phosphinic acid, methyl n-propyl phosphinic acid, methane-bis (methyl phosphinic acid), ethane-1, 2-bis (methyl phosphinic acid), hexane-1, 6-bis (methyl phosphinic acid), benzene-1, 4-bis (methyl phosphinic acid), tolyl phosphinic acid, diphenyl phosphinic acid, dithiophosphoric acid, or mixtures thereof.
13. The high voltage connector of claim 12, wherein the phosphinate salt is zinc diethylphosphinate, aluminum diethylphosphinate, or a combination thereof.
14. The high voltage connector of claim 12, wherein the flame retardant system further comprises a salt of phosphoric acid.
15. The high voltage connector of claim 14, wherein the flame retardant system comprises a metal phosphite, a metal phosphonate, or a combination thereof.
16. The high voltage connector of claim 14, wherein the flame retardant system comprises melamine pyrophosphate, melamine polyphosphate, piperazine orthophosphate, piperazine pyrophosphate, piperazine polyphosphate, or a combination thereof.
17. The high voltage connector of claim 1, wherein the flame retardant system further comprises an inorganic compound.
18. The high voltage connector of claim 17, wherein the inorganic compound comprises zinc borate.
19. The high voltage connector of claim 1, wherein the flame retardant system has a halogen content of about 1000ppm or less.
20. The high pressure connector of claim 1, wherein the deionized water phase has a pH of about 4 to about 8 72 hours after forming an aqueous dispersion containing 70wt.% deionized water phase and 30wt.% of the polyamide composition.
21. An electric vehicle comprising a powertrain comprising at least one electric propulsion source and a transmission connected to the propulsion source by at least one power electronics module, wherein the electric vehicle comprises the high voltage connector of claim 1.
22. The electric vehicle of claim 21, wherein the high voltage connector of claim 1 electrically connects the propulsion source to the power electronics module and/or the power electronics module to the transmission.
23. The electric vehicle of claim 21, further comprising a charging connector for plugging into a charging port of the vehicle, wherein the charging connector comprises the high voltage connector of claim 1.
24. The electric vehicle of claim 21, wherein at least one electric machine electrically connects the power electronics module to the transmission, wherein the high voltage connector of claim 1 electrically connects the power electronics module to the electric machine, and/or the electric machine to the transmission.
25. The electric vehicle of claim 21, wherein the propulsion source comprises a battery.
Claims (25)
1. A high voltage connector for an electric vehicle, the connector comprising a connector portion comprising an electrical pin and a protector extending from a base and surrounding at least a portion of the electrical pin, wherein the base, the protector, or a combination thereof comprises a polyamide composition comprising about 20wt.% to about 70wt.% of at least one polyamide, about 10wt.% to about 60wt.% of inorganic fibers, and about 10wt.% to about 35wt.% of a flame retardant system comprising at least one halogen-free organophosphorus compound, further wherein the polyamide composition exhibits a comparative tracking index of about 600 volts or more determined according to IEC 60112:2003 at a thickness of 3 millimeters and a V0 rating determined according to UL94 at a thickness of 0.8 mm.
2. The high voltage connector of claim 1, wherein the polyamide composition exhibits a tensile modulus of about 8500MPa or greater as determined according to ISO test No. 527-1:2019.
3. The high voltage connector of claim 1, wherein the wall thickness of the protector is about 0.8 millimeters to about 2 millimeters.
4. The high voltage connector of claim 1, wherein a periphery of the guard extends beyond an end of the electrical pin.
5. The high voltage connector of claim 1, wherein the protective member comprises a polyamide composition.
6. The high voltage connector of claim 1, wherein the connector further comprises a second connector portion comprising a receptacle for receiving the electrical pin and a protector extending from the base and surrounding at least a portion of the receptacle.
7. The high voltage connector of claim 6, wherein the base of the second connection portion, the protector of the second connection portion, or a combination thereof comprises the polyamide composition.
8. The high voltage connector of claim 1, wherein the polyamide comprises an aliphatic polyamide.
9. The high voltage connector of claim 9, wherein the polyamide composition comprises a combination of nylon-6 and nylon-6, 6.
10. The high voltage connector of claim 1, wherein the inorganic fibers comprise glass fibers.
11. The high voltage connector of claim 1, wherein the flame retardant system comprises a phosphinate salt having the general formula (I) and/or the general formula (II):
wherein, the liquid crystal display device comprises a liquid crystal display device,
R 7 and R is 8 Independently hydrogen or a substituted or unsubstituted straight, branched or cyclic hydrocarbon group having 1 to 6 carbon atoms;
R 9 is a substituted or unsubstituted straight, branched or cyclic C 1 -C 10 Alkylene, arylene, arylalkylene, or alkylarylene;
z is Mg, ca, al, sb, sn, ge, ti, zn, fe, zr, ce, bi, sr, mn, li, na, K and/or protonated nitrogen group;
y is 1 to 4;
n is 1 to 4; and
m is 1 to 4.
12. The high voltage connector of claim 1, wherein the phosphinate is a metal salt of dimethyl phosphinic acid, ethyl methyl phosphinic acid, diethyl phosphinic acid, methyl n-propyl phosphinic acid, methane-bis (methyl phosphinic acid), ethane-1, 2-bis (methyl phosphinic acid), hexane-1, 6-bis (methyl phosphinic acid), benzene-1, 4-bis (methyl phosphinic acid), tolyl phosphinic acid, diphenyl phosphinic acid, dithiophosphoric acid, or mixtures thereof.
13. The high voltage connector of claim 12, wherein the phosphinate salt is zinc diethylphosphinate, aluminum diethylphosphinate, or a combination thereof.
14. The high voltage connector of claim 12, wherein the flame retardant system further comprises a salt of phosphoric acid.
15. The high voltage connector of claim 14, wherein the flame retardant system comprises a metal phosphite, a metal phosphonate, or a combination thereof.
16. The high voltage connector of claim 14, wherein the flame retardant system comprises melamine pyrophosphate, melamine polyphosphate, piperazine orthophosphate, piperazine pyrophosphate, piperazine polyphosphate, or a combination thereof.
17. The high voltage connector of claim 1, wherein the flame retardant system further comprises an inorganic compound.
18. The high voltage connector of claim 17, wherein the inorganic compound comprises zinc borate.
19. The high voltage connector of claim 1, wherein the flame retardant system has a halogen content of about 1000ppm or less.
20. The high pressure connector of claim 1, wherein the deionized water phase has a pH of about 4 to about 8 72 hours after forming an aqueous dispersion containing 70wt.% deionized water phase and 30wt.% of the polyamide composition.
21. An electric vehicle comprising a powertrain comprising at least one electric propulsion source and a transmission connected to the propulsion source by at least one power electronics module, wherein the electric vehicle comprises the high voltage connector of claim 1.
22. The electric vehicle of claim 22, wherein the high voltage connector of claim 1 electrically connects the propulsion source to the power electronics module and/or the power electronics module to the transmission.
23. The electric vehicle of claim 21, further comprising a charging connector for plugging into a charging port of the vehicle, wherein the charging connector comprises the high voltage connector of claim 1.
24. The electric vehicle of claim 21, wherein at least one electric machine electrically connects the power electronics module to the transmission, wherein the high voltage connector of claim 1 electrically connects the power electronics module to the electric machine, and/or the electric machine to the transmission.
25. The electric vehicle of claim 21, wherein the propulsion source comprises a battery.
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US63/162,054 | 2021-03-17 | ||
US202163233512P | 2021-08-16 | 2021-08-16 | |
US63/233,512 | 2021-08-16 | ||
PCT/US2022/019733 WO2022197525A1 (en) | 2021-03-17 | 2022-03-10 | High voltage connector for use in an electric vehicle |
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