AUTOMOTIVE | COMPOUNDS FOR EVs
Above: Emerging EV front panel concepts integrate sensors, lighting signatures and brand-identify- ing elements, according to SABIC
integration of safety sensors, cameras and driver assistance functions, for example.” SABIC sees OEMs looking for material solutions
that enable seamless integration of components with lighting and branding elements and other design features. “Our SABIC team is engaged with many OEMs on innovative front panel concepts and multiple vehicles have used Lexan resin, our polycarbonate material, for this application. The material meets a number of requirements, such as transparency, durability and design freedom – which, importantly, can allow for the optimal integration of these multiple features,” says Umama- heswaran. “Other opportunities for thermoplastic compounds include the vehicle trunk, front-end module and dash panel. SABIC has proven materi- als to support requirements for these applications.”
Right: This polymer-based EV battery pack concept from SABIC saves up to 10% in weight on a component basis and improves energy density
Battery moves Umamaheswaran says OEMs and battery suppliers are continually looking to lower the system costs of their battery pack designs and to optimise indi- vidual components to reduce mass and improve flame retardancy, electrical isolation, design-for- assembly, mechanical performance and crashwor- thiness. He sees the low density of plastic com- pounds, together with the design flexibility inherent in processing methods such as injection moulding, as real attractions. The high voltage power systems of EVs place new demands on plastics. Improved fire-retardant properties, based on halogen and bromine-free options to address environmental concerns, are required without compromising the flow character- istics needed to enable development of thin wall solutions. SABIC says it has materials that can deliver against those needs including a recently launched non-halogenated, non-brominated flame retardant polypropylene family, which includes short and long glass fibre reinforcements. Umamaheswaran adds that meeting structural
72 COMPOUNDING WORLD | April 2021
requirements for next-generation EV battery packs and related components is a challenge that requires innovative solutions to support large part manufacturing, assembly and bonding of plastics with other materials as well as flammability protec- tion. To help address this challenge, the company’s automotive team has developed a BEV battery pack concept based on lightweight thermoplastic materials. In the plastic-intensive design, individual components of the full battery pack system can be 30-50% lighter than equivalents in incumbent metals. In addition to the weight saving, easier stacking of cells in their modules, improved thermal control, and enhanced crashworthiness can realise an energy density boost in platform efficiency. Flame retardant materials are used for key parts in the design, including the battery tray, covers, and module boxes and lids. Another area of EV development is the ongoing
trend to complex automotive lighting designs using light-emitting diodes (LEDs). Design ele- ments such as wider, larger and thinner forward and rear lighting components call for materials that enable thin walls, aggressive styling with sharp draft angles, and high aesthetics. The lower operating temperature compared to incandescent bulbs has allowed PC to be used, particularly in bezels, where it may be coloured or metallised. Due to its attractive aesthetics and impact resist- ance, PC is currently the most commonly used thermoplastic for bezels, says SABIC. “The capabilities of LEDs have helped lighting become one of the primary differentiators for today’s cars and trucks,” says Sergi Monros, Vice President of SABIC’s Performance Polymers & Industry Solutions business group. “To take full advantage of the complex designs made possible with LEDs, lighting manufacturers need break- through materials. Our portfolio of high-flow Lexan
www.compoundingworld.com
IMAGE: SABIC
IMAGE: SABIC
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82
