At the PCIM Europe 2025 event, SABIC is presenting its latest advancements in specialty thermoplastics aimed at addressing challenges associated with higher-voltage electrical applications. The company highlights voltage derating test results for ELCRES HTV150 film used in Nichicon capacitors and introduces a new ULTEM resin suitable for magnet wire insulation.
SABIC, recognized globally in the chemical industry, is showcasing its high-heat specialty thermoplastics tailored for demanding electrical applications, including those used in electric vehicles (EVs). Among the featured products are Nichicon Corporation capacitors made with ultra-thin ELCRES HTV150 dielectric film. These capacitors are designed to operate at temperatures up to 150°C with minimal voltage derating. Two technical presentations will discuss these features during the event. Additionally, SABIC unveils a new extrusion grade of ULTEM resin that offers productivity benefits over traditional materials used in EV motor magnet wire insulation.
Sergi Monros, vice president of SABIC Polymers, Specialties BU, stated: “Higher voltages are a common theme across electrical applications from connectors and capacitors to wire and cable. While high voltages can increase operational efficiency, they present challenges. SABIC continues to lead and innovate in this space. Our specialty materials perform well under exposure to high voltages, high temperatures and harsh conditions, helping customers deliver next-generation electrified components.”
The impact of elevated temperatures on polymer film capacitors' rated voltage is significant. Capacitors using biaxially oriented polypropylene (BOPP) film may see up to a 50 percent reduction at 125°C or above. However, testing by Nichicon revealed that capacitors utilizing SABIC’s ELCRES HTV150 dielectric film experienced minimal derating—4.8 percent at 130°C and 14 percent at 150°C.
Adel Bastawros, Ph.D., Chief Scientist at SABIC, will discuss these findings on May 6th at the E-Mobility & Energy Storage Stage and again on May 8th at the PCIM Conference.
With demands increasing for faster charging and greater range in EV motors reaching up to 800V, improved magnet wire insulation is necessary. Compared to extruded polyether ether ketone (PEEK) insulation, SABIC’s new ULTEM resin eliminates the need for primer while providing low Dk values at thinner gauges—up to 30 percent thinner—reducing weight and saving space.
Furthermore, unlike thermoset polyimide enamel coatings that emit volatile organic compounds (VOCs), which pose regulatory challenges, this new resin avoids such emissions entirely. It supports mono-layer extrusion requiring only one pass compared to enamel's multiple passes.
SABIC's exhibit also includes solutions like hybrid metal-plastic DC-DC converter housings for EVs that offer weight reduction versus all-aluminum designs and fast charging units incorporating various SABIC materials. Stationary energy storage applications are also displayed alongside other components made from ULTEM and NORYL resins as well as LNP copolymers with high comparative tracking index (CTI).
PCIM Europe 2025 takes place from May 6-8 in Nuremberg, Germany.
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