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Evolving EV hardware Since its inception, EV hardware design has continued to evolve. Due to this, there has been an increasing demand for enhanced fluid/oil formulations. For example, many current drive unit designs feature a single fluid that can lubricate the gears and bearings and provide a direct cooling option for the e-motor. Other fluids are designed to perform different functions and deliver different benefits to each component – electric motor, gearbox, and battery/ electronics – as highlighted in Table 1 below.
Table 2: Key Properties of SpectraSyn™ MaX 3.5 PAO * Publicly available data, ** ASTM method D5950 only covers up to -66
Energy efficiency and driving range testing results
Table 1: Lubrication and cooling demands of new EV hardware
A primary challenge is the viscosity of the base stock. Low viscosity is traditionally required for cooling and efficiency, while higher viscosity is needed for lubrication and durability. Formulating to the proper viscosity for the specific electric drive unit design enables the fluid to deliver an optimal balance between energy efficiency and mechanical protection over the full range of operating conditions.
Pushing hydrocarbon fluid performance to new limits SpectraSyn™ MaX 3.5 PAO synthetic base stocks offer unique attributes, including: • Exceptional balance of both low viscosity and lower volatility versus alternatives (LVLV)
• Excellent low temperature properties • Improved oxidative stability • Enhance lubricity and traction • Improved flashpoint versus conventional PAO (c-PAO)
Through this unprecedented balance of low viscosity and low volatility, SpectraSyn™ MaX 3.5 PAO enables lubricant formulators to deliver step-out fluid performance, helping automakers meet their fuel economy and energy efficiency goals. Benefits include: • Fuel economy improvements for engine oil (EO) and driveline
• Energy efficiency for EV driveline • Enhanced durability for extended oil drain intervals
SpectraSyn™ MaX 3.5 PAO products outperform existing Grp. III/III+ and c-PAO base stocks, enabling next-generation fluid performance as shown in Table 2.
28 LUBE MAGAZINE NO.185 FEBRUARY 2025
A series of WLTC (Worldwide harmonised light-duty test cycle) efficiency tests that compared Group III and Group III+ formulations against SpectraSyn™ MaX 3.5 PAO-based formulations were conducted using the Electric Drive Units (EDU) of different EVs by ISP Salzbergen, Germany. The results of this independent testing enabled energy efficiency to be evaluated compared to a reference fluid.
Test 1: VW APP310 energy efficiency testing Figure 3 shows test results from a VW APP310 EDU that demonstrated: • E-fluid formulations based on SpectraSyn™ MaX 3.5 PAO delivered moderate to significant energy efficiency benefits.
• The base oil in a formulation has a greater positive impact on the EDU efficiency than the additive package.
• Results and statistical data generated demonstrate reduced energy losses which can translate into improved driving range.
Figure 3: WLTC Efficiency testing on a VW APP310 EDU
Test 02 formulation: Group III, KV100 = 4.5 cSt. Thickener: PMA Test 12 formulation: SpectraSyn™ MaX 3.5 PAO, KV100 = 4.5 cSt. Thickener: PAO 150 Test 13 formulation: Group III, KV100 = 4.5 cSt. Thickener: PAO 150 Test 16 formulation: SpectraSyn™ MaX 3.5 PAO, KV100 = 4.5 cSt. Thickener: PAO 150, different additive package than the other formulations.
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