The transformation from the combustion to the electric engine entails several imponderabilities for the plastics industry. In part, electric drives have completely different material requirements which are becoming specifically evident with the increasing use of appropriate vehicles.

In electric vehicles, the change in engine technology also entails new requirements for the plastic materials used

Flame Retardancy, Heat and Tracking Resistance of Electric Vehicles

Elektromotoren

Antriebe

Kfz-Elektronik

Elektronik

Elektromobilität

Mobilität

Kunststoffe

Photonik

Optik

Polyamide

Kunststoff Werkstoffe

Thermoplaste

Elektronische Bauelemente

Leistungselektronik

Technische Kunststoffe

Hochleistungskunststoffe

Drivers of Electromobility

Replacing metal with polyamides (PA) in components can not only reduce weight and costs, but also offers developers greater design freedom. However, this requires materials with improved mechanical properties.

 A 3-point bending test showed that the maximum necessary  work of fracture for Ultramid XP grades which exceeds that of comparable PA6 and PA66 grades

16:9

Special Polyamides 6 Match the Properties of Polyamide 66

Automotive

Metal Substitution with Improved PA

Teknor Apex presents three halogen-free FR glass-reinforced polyamide compounds with UL94 ratings of V0.

Application example: engine cover in the automotive industry

Kunststoff

Bauwesen

Baustoffe

Faserverbundwerkstoffe

Andere Werkstoffe

Glass-Reinforced and Halogen-Free Flame-Retardant

Electrical architecture in an E-car is significantly more challenging than for conventionally powered vehicles. Particularly for insulation of high-voltage (HV) components, the demands on the materials used are increasing. With specially-tailored materials for electric vehicles, challenges in automotive high-voltage technology can be overcome.

Insulation of high-voltage components in electric vehicles makes high demands on the materials used

Polyamide Specialties for Electromobility

High Voltage in Cars

The Chinese automotive manufacturer Geely will in the future use a polyamide 6 (PA6) from Lanxess for front-end (FE) carriers in its vehicles.

The front-end carrier for vehicles by the Chinese manufacturer Geely will be made of a PA6 from Lanxess in the future. © Lanxess

 PA for a Front-End Carrier

Most of the energy in a crash is absorbed by metal parts. A new additional polyamide (PA) crash absorber has for the first time been integrated into the front end of the Mercedes-Benz S-Class. The advantage is that an additional loadpath could be added without significantly increasing the mass of the car.  Close cooperation between the project partners and the use of suitable simulation tools were key to successful realization of this project.

As part of the safety concept in the front end of the latest S-Class, Mercedes-Benz uses a crash absorber made from polyamide.

Crash Absorbers made from PA for the Front End Carrier of the Mercedes-Benz S-Class

Kfz-Sicherheit, passiv

Kfz-Systeme

Kraftfahrzeugtechnik

Accident Protection with Plastics

Electric-vehicle makers looking for fresh impetus are turning to thermoplastics, as these can be used to  improve the safety, performance and sustainability of the vehicles. Initial application areas for manufacturers can be found in a multitude of components ranging from battery cases to busbars, cooling lines and seals. Things become very interesting when material suppliers offer support in the form of CAE and injection molding analyses.

Thermoplastics play an important role in the batteries of electric vehicles. They help to keep battery temperatures in the optimal range for a long service life and high performance. 

Improving the Performance of Electric Vehicles with the Right Materials

Electric, Environmentally Friendly, Thermoplastic

The conditions in electric vehicles place high demands on the materials used. Therefore, automakers and suppliers must resort to expensive, high-performance plastics. For many applications, cost-effective alternatives are plastics whose properties have been greatly improved by means of treatment with high-energy electron beams.

Fig. 1. Crosslinked engineering plastics can be used for many different applications in electric vehicles.

Irradiation Crosslinking Replaces High-Performance Plastics with Cheaper Polymers

Strahlenvernetzung

Kunststoffverarbeitung: Verfahren

Kunststoff-Aufbereitung

Electron Booster for Electric Vehicles

Electromobility in particular, but also many other electrical applications, are asking for ever higher demands regarding the electrical properties of thermoplastics. This raises the question of whether the polymers commonly used in this area can still meet these demands. The plastics manufacturer, Lanxess, has now investigated how suitable, for example, polyamide and polybutylene terephthalate are for use at higher voltages and temperatures.

How Suitable Are PA and PBT for High-Voltage Applications?

Polybutylenterephthalat

Against the Current

BASF is expanding its portfolio of flame-retardant engineering plastics for electric vehicles. The new PA66 type Ultramid A3U44G6 DC OR is reinforced with 30 % glass fibers.

The new PA66 type is flame-retardant and meets all the criteria of color stability and heat aging resistance. This enables long-lasting color coding, which is safety-relevant in the sensitive area of high voltages in electric cars.

Farbstoffe

Additive

Flame-Retardant and Color-Stable

DSM sells its Engineering Polymers business to Lanxess and the financial investor Advent. In return, the two companies are setting up a joint venture to which Lanxess is also contributing its PA and PBT business.

Lanxess is outsourcing its engineering plastics business to the joint venture.

Streifinger, Florian

Wirtschaft

Lanxess and Advent to Buy DSM‘s Engineering Plastics Business

With the change from internal combustion engines to hybrid and electric vehicles, peak operating temperatures have dropped from 135 °C to 110 °C. At the same time, the number of operating hours compared to combustion engines has increased nine-fold. This has an influence on material selection.

A Comparison of PA66 and PPA for Electric Vehicles

Higher Performance in Water

A focal point of the Lanxess booth at the show this year will be materials for electromobility.

The demonstrator of a near-series- production housing for electric vehicle batteries is one of the highlights at  the Lanxess booth.

Messe K-Kunststoffmesse

kunststoffe-international.com

kunststoffe.de

Demonstrator for EV Battery Housings

Engineering and high-performance plastics as alternatives to metals will be one of the highlights at Lehvoss’s booth.

The smartphone holder consists of recycled PA66 and has been reinforced with 50 % glass fibers.

Focus on Metal Substitutes

Electric vehicles can be charged not only at charging stations, but also wirelessly. Here, the energy exchange takes place between an induction coil positioned in the ground and a receiver coil mounted in the e-car.

Wireless charging could increase the range, and therefore the acceptance of electromobility.

Flame Retardant Polyamide for Inductive Charging Systems

No Cable thanks to Suitable Compounds

Superior Surface Quality in Automotive Interiors

Premium-quality automotive interior surfaces are becoming increasingly important from the customer’s point of view. This insight prompted Asahi Kasei to develop its Leona SG series of semi-aromatic polyamides (PA), which the Japanese group will be presenting at this year’s trade show Fakuma.

They are available in grades containing 40, 50 and 60  % glass fiber-reinforcement. According to the company, the PAs feature improved flowability and provide a very good surface finish without the need for additional treatment or coating despite their high glass fiber content. Intended applications for the material include venting blades, armrests, covers, and door handles. Asahi Kasei claims that the material also has very good inherent mechanical strength, even when exposed to moisture. For example, the 50  % glass fiber-filled SG105 in the conditioned state is said to substantially outperform semi-aromatic and standard polyamides. Whereas standard PA66 undergoes a deterioration in tensile modulus of about 30 % compared to the unconditioned state, SG105 maintains its performance. In addition, the flexural strength of SG105 is 8 % better than that of comparable semi-aromatic polyamides and up to 25 % better than that of standard PA66, says the polymers producer. The materials’ high flowability is also said to enable thin-walled constructions and material savings.

Asahi Kasei Europe GmbH  

https://www.asahi-kasei.eu

Ausgabenartikel

Automotive interiors require materials with good mechanical properties that will also produce premium-quality surfaces

2021-09-09 werkstoffe_Asahi Kasei

Messe Fakuma

issue 02/2023

issue 01/2023

issue 09/2022

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