New PPS grades from SABIC target insulation challenges in high-voltage power modules
Last update on Jul 20, 2026
If you're specifying insulation materials for IGBT power modules running at 800V and above, you're holding several requirements at once. They include thermal shock resistance from rapid power cycling, electrical insulation performance that survives years of heat aging, and flame-retardancy that holds up even as designs shrink to thinner walls. Fall short on any one of these, and the reliability of the entire power module is at risk.
SABIC has added two grades built for this profile to its LNP™ THERMOCOMP™ portfolio: OFM76XXP and OFM76EXP compounds, based on polyphenylene sulfide (PPS) resin.
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Retain 90% strength and insulation performance through thermal aging
The OFM76XXP and OFM76EXP compounds are rated CTI-PLC 0, the top level on the comparative tracking index. Like other PPS resins at this rating, they're designed to hold strength and insulation performance through thermal aging. According to SABIC, the new grades add improved toughness to that profile. This addresses a trade-off formulators have had to accept with PLC 0-rated PPS grades: aging performance without added brittleness.
The compounds are built on a polyphenylene sulfide (PPS) resin base. This resin base also lets the grades combine impact strength, dimensional stability and thermal shock resistance in one material. These are three properties formulators often have to trade off against each other when specifying insulation for high-voltage power electronics.
SABIC reports that the OFM76XXP and OFM76EXP compounds retain 90 percent of their strength and insulation capability after 1,000 hours of heat aging at 200°C. Compared with polybutylene terephthalate (PBT) and polyphthalamide (PPA) materials used in similar applications, SABIC states the new grades offer better dimensional stability and resistance to thermal shock. The grades also maintain UL94 V0 flame retardancy at a 0.4mm wall thickness, supporting thinner, more compact insulation designs.
The OFM76EXP grade adds:
- Enhanced laser marking capability
- The highest impact strength of comparable materials, according to SABIC
- Adhesion to silicone-based sealants
- Crack resistance
Both grades can be produced in white or light colors. This keeps compulsory QR codes printed on IGBTs visible.
"Higher voltages, greater power densities and miniaturization are driving manufacturers of critical power electronic devices like IGBT switches to choose materials that help enhance stability and power," said Sergi Monros, vice president, Specialties Business at SABIC. "Our experts stay ahead of changing customer requirements through proactive development of specialty thermoplastics that surpass existing solutions. We continue to enhance our renowned portfolio of LNP compounds with new capabilities, higher performance and extended reliability."
Application in DC power transmission systems and renewable energy infrastructure
These grades have the potential to be used in DC power transmission systems, high-voltage inverters and breakers, integrated busbar brackets, and renewable energy infrastructure, as well as industrial automation applications such as robotics. That range circles back to the challenge this article opened with: IGBT module insulation base plates in power modules for high-voltage electric vehicle traction inverters at 800V and above, and fast chargers.
In one line: OFM76XXP and OFM76EXP combine the highest CTI rating available in PPS with added toughness, insulation performance that holds through heat aging, and thin-wall flame retardancy, in a single material.
You can review the full technical datasheets for LNP™ THERMOCOMP™ portfolio, and request samples directly, in the Master Catalog of Plastics. To track new PPS and power-electronics grades as they're added, you can also sign up for newsletter updates.
Image credits: SABIC