PPSU Is Designed to Insulate Conductors Even in Hot Oil up to 200 °C (392 °F)

Insulation and Thermal Management PPSU Is Designed to Insulate Conductors Even in Hot Oil up to 200 °C (392 °F)

2026-10-07 Source: Press Release | Translated by AI 2 min Reading Time

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As power outputs increase and electrical systems become more compact, the demands placed on insulation and cooling materials also rise. BASF is positioning its PPSU Ultrason P for use in cables and conductors in electric vehicles—even when in direct contact with hot oil.

Ultrason (PSU, PESU, PPSU) is suitable for E&E components used in electric mobility or AI infrastructure, such as connectors for fiber-optic cables.(Image: BASF) — Ultrason (PSU, PESU, PPSU) is suitable for E&E components used in electric mobility or AI infrastructure, such as connectors for fiber-optic cables.
(Image: BASF)

Electrification not only places greater demands on semiconductors, batteries, and power electronics. The materials used in conductors, cables, and cooling systems must also withstand higher temperatures as well as chemical and mechanical stresses. BASF is therefore expanding the range of applications for its high-performance plastics in the Ultrason family, including applications in e-mobility.

Ultrason P is of particular interest for electric drive and power systems. Polyphenylsulfone, or PPSU for short, can be processed by extrusion and is suitable for both cable jackets and the electrical insulation of aluminum and copper wires.

Electrical insulation up to 200 °C

According to BASF, the material remains usable even when exposed to hot oil at temperatures up to 200 °C. It combines chemical resistance and flexibility with stable electrical insulation properties at high temperatures.

This is particularly relevant for compact electrical systems, in which conductors and insulating materials are increasingly exposed to higher thermal stresses. As power density increases, it is not only the maximum temperature that becomes important: dimensional stability, chemical resistance, and electrical performance must also be maintained over extended periods of time.

BASF also views Ultrason P as a potential alternative to PFAS-containing polymers, which have been used to date for cable sheathing and conductor insulation. However, in its official press release, the company does not specify which specific PFAS materials can be replaced or for which automotive applications approvals have already been granted.

Materials for Cooling Circuits in Electric Vehicles

In addition to electrical insulation, BASF’s Ultrason family also addresses thermal management. The polyarylethersulfones are intended for use in applications such as pipe fittings, manifolds, and fans. The company specifically cites electric vehicles and industrial cooling systems as areas of application.

The material family includes PESU, PSU, and PPSU. They all share high heat resistance, electrical insulation, dimensional stability, inherent flame retardancy, and chemical resistance. Different viscosities are designed to enable both thin-walled, complex injection-molded parts and extrusion applications.

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