Vehicle electrification drives automotive trends while turbocharged engines get hotter

At the NPE 2024 Plastics Show, Jose Chirino, Technical Director at Envalior, Eric Jaarda, Business Development Manager at SABIC High Performance, and Jason Merkle, Technical Manager at Chase Plastic Services Inc., were panelists for the Automotive Industry Plastic Materials Update presented by Chase Plastics. Topics discussed included the latest polymer developments, key market trends, plastics that have the potential to transform the sector, and the importance of sustainability in material choices.

All three panelists agreed that the electrification of vehicles is driving many trends in the automotive industry. Chirino noted that lightweight design, cost reduction, 800V charging, 48 bus system, and thermal runaway protection are the current trends he sees Envalior addressing.

There are many opportunities for metal replacement, and cost down is just as important as ever to OEMs because EVs cost approximately 30 percent more than ICE vehicles and manufacturers are working to decrease vehicle costs. Battery charging on an 800 V infrastructure is another important trend because everyone wants the ability to charge EV batteries quickly. Also, vehicles’ electronic systems demand a higher voltage battery – for years 12 V batteries have been used – but this is changing and the 48 bus system has the voltage needed to keep all electronic systems running.  

“Vehicle needs are changing to a certain degree because of electrification,” said Chirino. “Although EVs are becoming a norm, ICE vehicles will still be manufactured. At Envalior, we not only focus on materials for electrification, but we continue to address the need for engineered materials to withstand higher temperatures for under the hood applications in ICE vehicles.” 

Temperatures in ICE vehicles continue to increase because most engines are turbocharged and small. The components in the engines must stand up to the high temperatures. A material that is heat stabilized and withstands high temperatures is Akulon Diablo. This high heat resistant polyamide 6/66, ideal for metal replacement in under-the-hood applications up to 220°C. We created Akulon Diablo as a material to help customers tackle the ever-challenging temperature range within smaller, hotter turbo engines. As a result, the latest grade – Akulon Diablo HDT2500 – delivers a 3,000 hour continuous use temperature of up to 220°C without drop of mechanical properties.

Chirino also shared with attendees all of the possible cost / weight reduction in key applications when utilizing Envalior materials, including:

• Battery technology: thermal runaway and plastic enclosures
• Lightweight design: air springs and cross car beams
• Fuel system
• High Voltage
• E-Motors
• Fuel cells
• Auto E&E 

Chirino also touched upon Envalior’s technologies including welding, foaming, thermal management, EMI Shielding, Metal/Plastic hybrids, E-friendly materials, CAE, and PCF (Product Carbon Footprint) reduction.

“A clear trend for automotive OEMs is their interest in understanding the carbon footprint of the materials they use,” said Chirino. “Most of them have initiated CO2 reduction targets, and Envalior’s strategy is to offer various polymers with reduced PCFs, from recycled fishing nets in Akulon RePurposed, to the use of PIR glass fiber in various Durethan ECO grades, but also the use of bio-based monomers in the production of EcoPaxx and Arnitel grades.”

Plus, Envalior is much more than a materials provider – Envalior is a development partner.

“With Envalior’s expanded engineering polymer offering we have the right products for the right applications addressing the changes in the automotive industry.,” explained Chirino. “Some broad applications in which we support customers are actuators, thermal management systems, special requirements of fuel cells, lightweighting that needs to be proven and meet impact property standards of the OEMS – these are just a few examples of product development we partnered with customers on.”