TECHNOLOGY | COMPOUNDS FOR EVs
Right: Covestro’s Bayblend flame-retardant PC blends provide the dimensional stability and electrical properties needed for battery modules
enable space-saving thin-wall designs for cell frames, retainers and battery pack top covers. Furthermore, they provide good dielectric perfor- mance with a comparative tracking index (CTI) of 2 to help avoid electrical shorting among tightly packed cells. The new resins are also said to provide improved resistance to acid compared to PC, better resistance to moisture compared to PA, and a low specific gravity.
Below: Electrical charging stations can benefit from lightweight, impact resistant
performance of Covestro’s PC and PC blends
Beyond power Weight saving initiatives in the EV sector also extend beyond the powertrain. SABIC recently undertook a design study on automotive rear quarter windows to highlight the advantages of using its Lexan PC resins to save weight while creating differentiated styling, consolidating components, integrating functions and enhancing aerodynamics. The company says that the concepts reveal new opportunities to expand design freedom, control cost and reduce weight by replacing traditional glass. “As industry trends, such as vehicle electrification, continue to evolve, SABIC is seeing major new opportunities for our materials to radically change automotive styling, while simultaneously address- ing the longstanding challenges of weight-out, cost-out and sustainability,” says Abdullah Al-Otai- bi, General Manager, ETP & Market Solutions. “The latest concepts from our study aim to inspire exciting new window designs that address these needs by combining beautiful aesthetics with practical performance and established processing methods.”
SABIC says many of the new concepts feature curved wraparounds that seamlessly flow into other portions of the vehicle, while integrating rear lighting, door latches, D-pillar trims and even sunroofs. Such integrations and complex curvatures cannot typically be achieved with glass. Part and function integrations can enhance aerodynamics to improve battery efficiency and range while also
creating a highly streamlined look for the vehicle. PC has been considered for automotive glazing
applications on ICE vehicles in the past and there have been some successes. However, glass has remained the dominant option, which SABIC attributes mainly to its low cost for making simple curved components. However, the company sees disruptors such as EVs prompting the industry to re-imagine vehicle design. In the process, tradi- tional materials such as glass have come under scrutiny and there is a strong interest in replace- ment with safer, lighter, higher performing engi- neered plastics. The company has invested in development of a production plant to produce three component injection moulded sunroof elements to build competence in moulding large transparent and semi-transparent parts. A number of high-performance plastics have been developed by Covestro for automotive battery components such as cell holders, which must provide dimensionally accurate placement of the cells in the housing. These include flame-re- tardant PC blends from the company’s Bayblend FR range, which are said to offer good dimensional stability as well as good electrical properties and high impact strength. They enable tight tolerance production of dimensionally stable parts at the volumes required for battery manufacturing. The company has also developed a thermally conductive PC grade — Makrolon TC. This is intended to provide new options for cooling battery modules (thermal control is very important to ensure long battery life and, depending on the design of the battery system, to enable fast charging). Battery modules using the Makrolon TC materials could be used in electric vehicles, in stationary energy storage systems, and in replace- able batteries for cycles and scooters.
Charging systems harging systems are also a key area of development in the EV sector and demands for high speed charging will place heavy demands on plastics.
34 COMPOUNDING WORLD | April 2022
www.compoundingworld.com
IMAGE: COVESTRO
IMAGE: COVESTRO
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