COMPOUNDS | ELECTRIC VEHICLES
compounds outgassing, the company claims. Schwestka cites its recent development of a
lubricated PEI for the bearings of an electrically operated spoiler. “The spoiler operation needed to be silent over an entire temperature range from -40 to +90 C,” he explains . “In order to achieve this, we used a special lubricant system and modified the material so that the thermal expansion matched the metal components. The material also needed to be electrically conductive, because the spoiler assembly is suspended from the bearing during electrostatic painting.”
Below: Electric drive makers are yet to explore the full potential of plastics, according to BASF
Flame retardance BASF has developed a number of high perfor- mance plastic compounds for EVs, adding that the speed at which performance, weight, safety and efficiency of electric drive trains can be optimised will be a crucial factor in the success of electromo- bility. It says flame retardant plastics, in particular, will be required to enable savings to be made in terms of the weight and installation space required for high-voltage components. Current electronic drive systems are still primarily part of the metals industry, according to BASF. Until now, manufacturers of electric motors and power electronic components have been using housings made of steel or die-cast alumini- um but, as many of the components are now actively cooled, plastic solutions are now a possibil- ity for lightweight construction. It says its flame- retardant Ultramid grades A3U42G6 and B3U50G6 would be contenders for such applications. Housings that contain high-voltage electric components must also be electrically shielded to prevent compromising the surrounding area and metal coatings on the plastic housing parts are one
Lubricated PEI bearings developed for an electrically-operated spoiler by Witcom
IMAGE: WITCOM ENGINEERING PLASTICS
of the possible solutions that BASF is pursuing. In prototype projects with customers, it says it has been able to show that plastic housings manufac- tured using this process are lighter and more economical than comparable die-cast aluminium housings.
In addition to electromobility, BASF adds that highly automated driving will also revolutionise tomorrow’s vehicles and the number of sensors will increase significantly. It says it has already made a significant contribution to a number of sensitive electronic sensor technologies with its range of hydrolytically resistant PBT grades. However, it believes the the increasing level of automation will also see new sensors, such as radar, lidar (light detection and ranging), IR and ultrasonic sensors, find their way into cars. Celanese says its polymers are providing
effective and sustainable solutions for a variety of under-the-hood, interior and exterior parts for EVs. It says these range from improving battery perfor- mance, to lightweighting battery housings and thermal management. It is also targeting Passive Automation Driver Assistance Systems (ADAS) components such as cameras, radar, lidar, and high speed data connection systems.
Beyond the technical However, Celanese says the focus should not be all technical — driver experience and flexibility of interior design is another key area of application for plastics. As vehicles see increasing and more severe usage of interior control and communication systems, carmakers will require durable surface materials at lower cost that do not sacrifice appear- ance and quality. It says its MetaLX mould-in-colour polymers are one solution, offering designers and engineers high gloss and matt finishes, UV resist- ance, and scratch and mar protection. The company also highlights increased demand for recycled solutions. In addition to the ongoing
30 COMPOUNDING WORLD | April 2020
www.compoundingworld.com
IMAGE: SHUTTERSTOCK
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