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Electronics & Electric

Electronics & Electric

Electronics & Electric

Plastics for circuit protection: Wherever electric power flows, plastics must possess excellent electrical properties together with good mechanical characteristics and exhibit high heat resistance. 

Our materials cater for the increased demand for electrical components that are flame retardant, smaller but still deliver the same or even better performance. 

BASF’s E&E materials

Benefits

  • Excellent electrical performance
  • Good mechanical properties
  • High thermal stability
  • Secure handling 
  • Reduced fire risk
  • Meeting new design requirements
Emergency stop button made of Ultramid

Solutions for E&E applications

Electrical components for power distribution and controls

Circuit breakers

Circuit breakers protect circuits and reliably cut off the power supply in case of hazardous failures. This occurs in case of brief power surges as well as continuous overload.  
Miniature Circuit Breaker

Read more about using plastics in circuit breakers

An electrical cabinet comprises several circuit breakers, which control different electrical circuits. In case of failure that may cause a hazardous event, they "trip" and thus cut off the power supply within milliseconds.  

Reliability and reusability are the two key requirements for breakers: because a short circuit causes intense heat, failure would result in sparking and possibly a fire. In addition, circuit breakers need to be reusable after they get tripped, i.e. you simply flip the switch again and the safety function is restored. Plastics used for these circuit breakers thus must meet the high requirements for mechanical properties and fire behavior (glow-wire ignition test at 960°C). 

BASF offers a comprehensive portfolio to produce housings and other parts of circuit breakers. By using  Ultramid® (PA),  Ultradur® (PBT),  Ultraform® (POM) and Ultrason® it is possible to meet a wide range of requirements for applications in households as well as for highly specialized industrial applications. 

 

 

Switchgears and accessories

Switchgears are defined as the electrical equipment in industrial applications for the control, protection and automation of low-voltage installations (≤1000V a.c., ≤1500V d.c.).  

Read more about using plastics in switchgears and accessories

In addition to energy distribution, many additional tasks have to be addressed, such as ensuring the safety of employees and plant, efficient process control and supervision, or “soft” switching. Accordingly, there is great variety among the components: there are contactors, control gear, soft starters, circuit breakers, overload and current monitoring relays, and memory-programmable controls. 

Housing and the respective accessories for these components ensure safe operation of these utilities and are made of insulating materials such as polyamide (PA) and polybutylene terephthalate (PBT). 

BASF offers many grades of the engineering plastics Ultramid® (PA) and  Ultradur® (PBT) which, depending on the application, meet the high requirements for mechanical and electrical properties (e.g. CTI). This also requires a high heat deflection temperature (HDT) and heat aging resistance (e.g. TI, RTI) as well as excellent fire protection properties (UL94, Glow-wire testing). 

Terminal blocks

From control panels for industrial plants to fuse boxes in private homes: Terminal blocks ensure safe current transmission as well as safe wiring of installations.

Read more about using plastics in terminal blocks

Plastics used to manufacture terminal blocks must meet high requirements for fire protection and mechanical as well as thermal properties. In electrical engineering, terminals are used to connect wires and cables. Continuous safe contact has to be ensured for the connection – mechanical fixing ensures this. Terminal blocks can be arranged in any order on a mounting rail and installed with a simple snap.

This defines the mechanical properties required for this material: plastics used in this application must exhibit high elasticity and good toughness – or run the risk of breakage when snapping. Connections require sufficient stiffness and strength.

 

When handling electrical power, sparking and fires may occur – thus the highest requirements for fire behavior are industry standard (UL94 V-0, GWEPT 960). Other requirements include high temperature resistance and heat aging resistance.

Plastics have electrical insulating properties, which generally recommends them for electronic applications; in addition, high tracking resistance (CTI 600) is required for terminal blocks.

Terminals are produced in extremely large quantities by injection molding. Economic production requires short cycle times and low maintenance cost for injection molding tools and machinery. It is also necessary to be able to produce very low (0.4 mm) wall thicknesses with the plastic.

In addition, good colorability of the material plays an important role: Different colors of the terminal blocks serve to differentiate between different functions (e.g. neutral conductor, protective conductor, etc.) and ensure safe installation.

Due to the high requirements, unreinforced polyamides can be considered as materials. The PA66/6 copolyamide (Ultramid® C3U) from BASF’s extensive portfolio of engineering plastics is particularly suitable for use in terminal blocks.

Electrical components for connectivity

Plug connectors are used for detachable connections of electrical lines (e.g. for service purposes). Globally, there are numerous standards for these parts of connection technology, and materials for plugs and plug connectors are subject to strict testing as well.

Read more about using plastics in high and low voltage connectors

High-voltage connectors for electrified vehicles, combining electrical insulation, flame retardancy, and long-term durability.
The orange color of high-voltage connectors provides an immediate, safety-critical indication of elevated voltage. 
Ultradur® (PBT) combines long-term color stability with resistance to thermal aging, helping connector components remain clearly identifiable for at least ten years. As part of BASF’s non-halogenated flame-retardant portfolio, the material also offers high hydrolytic resistance and excellent electrical insulation, with a comparative tracking index of CTI 600. This combination supports durable performance while addressing key technical specifications and long-term material requirements.
Heavy-duty industrial connector housing designed for reliable electrical connections in demanding applications.
Low-voltage connector housings and components require dependable electrical insulation, mechanical strength, and thermal stability. Ultramid®(PA) and Ultradur®(PBT) support these requirements across a broad range of electrical and electronic applications, enabling material selection based on the connector’s specific performance needs.

Power electronics: Advanced Material Solutions for Electrification

In EVs, charging infrastructure, renewable energy systems, and industrial applications, advanced material solutions for electrification are essential. Engineering plastics by BASF, such as Ultradur® and Ultramid® and BASF’s unique engineering services drive innovation forward, enabling customers to accelerate development and shorten time-to-market.
Advanced power electronics component requiring high thermal stability, electrical insulation, and flame-retardant materials.

Read more about using plastics in power electronics

The transition toward electrification is driving unprecedented demand for high-performance power electronics in electric vehicles, charging infrastructure, renewable energy systems, and industrial applications. BASF supports this transformation with innovative material solutions for inverter housings, busbars, and IGBT components that combine electrical insulation, flame retardancy, thermal stability, and lightweight design.

Our extensive portfolio includes engineering plastics based on PA6, PA66, PBT, TPU, and PPA, enabling the replacement of metal components while delivering benefits such as improved design freedom, lower weight, reduced assembly effort, and a lower carbon footprint.

For high-voltage busbar applications, BASF materials offer excellent flame retardancy, high comparative tracking index (CTI up to 600), outstanding thermo-shock resistance, and long-term electrical performance at elevated temperatures. Simulation services support optimized component design and reliability.

In IGBT housings, BASF materials combine high flame-retardant performance (UL94 V-0), excellent electrical insulation, high CTI values, and strong temperature resistance, helping customers meet demanding safety and durability requirements.

Complementing its material portfolio, BASF provides a unique range of engineering services, including testing, simulation, and electrical performance validation, enabling customers to accelerate development and bring innovative power electronics solutions to market faster.

Suitable products include: Ultradur B4441G5, Ultramid Advanced N3U41G6, Ultradur B4450G5 (also available as HR grades), Ultramid A3U42G6, Ultramid B3UGM210.

Electrical components for household appliances

Plastics for electrical household appliances must meet a variety of requirements defined in the series of standards IEC 60335.

Read more about using plastics in electrical components for household appliances

BASF engineering plastics are used as electrical insulators (e.g. for plug connectors, sensors, actuators): The highly specialized Ultramid® (B3U50G6) flame-retardant grade is especially suitable for this application. 

This light-colorable grade reliably meets the household appliance standard IEC 60335–1 (glow-wire test, GWIT 800°C at 1 millimeter where standard only requires 775°C) and provides a particularly high flowability. The flame retardant­ system used in  Ultramid® (B3U50G6) is not halogen-based and contains no antimony compounds. This makes it possible to achieve good values with regard to smoke density and smoke toxicity as well as to comply with WEEE and RoHS directives. 

Electrical components for photovoltaic installations

Photovoltaic installations must meet stringent demands to obtain approval for their connection technology – both in terms of safety and in terms of service life.

Read more about using plastics in electrical components for photovoltaic installations

For the electronic components of these installations, BASF offers special grades of the engineering plastic Ultramid® (PA).

Photovoltaic installations and their connection technology, usually installed on roofs of houses and factory buildings, are directly exposed to the elements. Sun, rain and wind affect these installations, and in addition, fire protection regulations place high demands on the plastics used.

BASF has two grades of engineering plastics (Ultramid® A3X2G7 and Ultramid® A3XZG5) in its range which are particularly flame-retardant, very strong even at low wall thicknesses, resistant to chemicals, and particularly impact-resistant at low temperatures (UL standard 1703).

Ultramid® A3X  types are particularly suitable for plug connectors. Ultramid® A3X2G7 is extremely stiff so that plugs can be very thin. For example, this material meets the UL94 flammability standard V-0 class starting at a wall thickness of 0.8 mm and 5VA starting at a wall thickness of 1.5 mm. For junction boxes, Ultramid® A3XZG5 (UL 94 class 5VA) is the recommended choice.

Cable jackets

Cable sheathing for the protection of valuable and sensitive energy and control lines have to meet the highest requirements. Thermoplastic polyurethane by BASF - Elastollan® - meets the high demands for such wires and cables.

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FAQ

 

Q: Which engineering plastics are best suited for circuit breakers and electrical protection devices?

Engineering plastics for circuit breakers and electrical protection systems must combine electrical insulation, mechanical strength, heat resistance, and flame-retardant performance. BASF’s portfolio offers plastics with these properties, including Ultramid® (PA), Ultradur® (PBT), Ultraform® (POM), and Ultrason® (PSU, PESU, PPSU).

 

Q: What material properties are required for modern terminal blocks?

Terminal blocks require materials that deliver a combination of high electrical insulation, flame-retardancy, thermal stability, stiffness, toughness, and excellent tracking resistance (CTI). BASF's Ultramid® C3U is particularly suitable because it supports thin-wall designs, reliable snap-fit functionality, color customization, and compliance with demanding electrical safety standards such as UL94 V-0 and GWEPT 960.

 

Q: Which plastics are commonly used in photovoltaic connectors and junction boxes?

Photovoltaic connectors and junction boxes require materials that can withstand UV exposure, moisture, temperature fluctuations, and demanding fire-safety requirements. Flame-retardant engineering plastics with high chemical resistance and impact strength such as Ultramid® (PA) are commonly selected to ensure long service life and reliable performance in outdoor environments.