EV Charging Plugs and Sockets
EV Charging System
Government-mandated targets to reduce
fossil fuel emissions drive commercial
vehicle brands to invest in hybrid and EV
technology. Safe and reliable EV charging
plugs require insulating materials that
withstand up to 800V and more.
HV Connectors
EV Charging System
Vehicles require safe and reliable connectors to
enable a growing number of critical active
safety and driver assistance systems. Our
materials are trusted for manufacturing
high-performance connectors for millions of
new vehicles. We recently launched an
industry-first Arnite® PBT compound that
achieves a CTI of 600V and UL94-V0 at 0.8mm, as
well as hydrolysis resistance and a silicon
compression set well below any PA alternative.
Unlike competing PBTs that easily become
brittle, our Arnite® solution offers an elongation
at break comparable to PA66. As a polyester, its
orange color remains very stable after long-term
aging – unlike PAs prone to discoloration.
IGBT Frame
EV Charging System
Automakers continue to focus on high
voltage charging systems that increasingly
use high-power IGBT components with
dedicated frames – which need to offer high
dimensional stability, and resist extreme
temperatures and electro corrosion. We offer
a complete portfolio of Arnite® PBT, ForTii®
PPA and Xytron™ PPS compounds that
ensure UL94-V0 flame retardancy and
excellent insulative properties from -40°C up
to 180°C. Xytron offers high bonding strength
with silicon gels, excellent dimensional
stability and creep resistance, and ionic
content of less than 50ppm to reduce the
risk of electro corrosion.
Bus Bar
EV Charging System
Bus bars are an essential interconnection
system for various high voltage components
of EVs, such as the connection between the
inverter and the e-motor. These parts need to
be robust and offer high temperature and
thermal crack resistance. Our broad material
portfolio offers grades ideal for challenging
bus bar requirements. We also provide design
support to mitigate CTE mismatch issues with
copper and optimize glass fiber orientation –
ensuring the lowest thermal stress is
generated at the edges of copper strips.
Capacitor Housing
EV Charging System
Capacitor housings are essential components
in every high voltage system. Xytron™ PPS
grades enable these parts to achieve
best-in-class performance. The material
offers unmatched electrical insulative
properties, as well as a CTI of <175V to reduce
the risk of electrical tracking.
Fuel Cells
Fuel System
Ultra-pure materials that prevent ion
leaching and hydrolytic and heat aging
improve the efficiency and service lifetimes
of fuel cells. Our Xytron™ PPS compounds
demonstrate very low ionic leaching and
high mechanical strength to enhance the
lifetime efficiency of vehicles.
Hydrogen and Gasoline Tanks
Fuel System
Gasoline and hydrogen tanks for hybrid or
fuel cell vehicles need to withstand extreme
temperatures and offer strong barrier
properties to keep passengers safe. Akulon®
Fuel Lock is superior to traditional HDPE and
metal solutions due to its high strength, low
permeation and easy processing behaviour.
Our advanced bio-based EcoPaXX® PA410
material is ideal for producing more
sustainable tanks that offer increased
chemical resistance and exceed gasoline
permeation requirements set by EURO VII
and Carb III standards.
Electric Water Pump (Housing and Impellers)
Thermal Management System
In EVs, thermal management systems (TMS)
are critical to keeping battery packs within
the optimal temperature range – to ensure
EVs are safe and improve engine efficiency
and service lifetimes. XytronTM is ideal for
developing TMS components such as electric
water pump housings and impellers that
require the highest hydrolysis and heat aging
resistance. ForTii® PPA and EcoPaXX® PA410
also offer proven performance in TMS
components.
Thermal Management Module (TMM)
Thermal Management System
In EVs, thermal management systems (TMS) are
critical to keeping battery packs within the
optimal temperature range – to ensure EVs are
safe and improve engine efficiency and service
lifetimes. XytronTM is ideal for developing TMS
components such as thermal management
modules that require the highest hydrolysis
and heat aging resistance. ForTii® PPA and
EcoPaXX® PA410 also offer proven performance
in TMS components.
Coolant Connectors
Thermal Management System
In EVs, thermal management systems (TMS)
are critical to keeping battery packs within
the optimal temperature range – to ensure
EVs are safe and improve engine efficiency
and service lifetimes. XytronTM is ideal for
developing TMS components such as coolant
connectors that require the highest
hydrolysis and heat aging resistance. ForTii®
PPA and EcoPaXX® PA410 also offer proven
performance in TMS components.
High-Speed Bearing Cages
E-Powertrain System
Vehicle electrification trends are changing
performance requirements for high-speed
bearing cages. To develop lighter, smaller
e-motors that generate the right amount of
power, designers need to reduce torque while
boosting rotation speeds. Downsizing the e-axle
requires miniaturized, thin-walled bearing
cages. Thinner bearings that operate at faster
speeds need to offer higher stiffness over a
wider temperature range to prevent part
damage. Materials like PA66 offer limited
resistance to high-temperature grease that
lubricates high-speed bearings. Stanyl® PA46
offers proven high-performance for e-motor
applications due to its excellent strength,
stiffness and thermal properties – tested and
approved by leading Tier 1s and OEMs.
E-Motor Resolver
E-Powertrain System
Vehicle electrification trends are changing
performance requirements for e-motor
resolvers. Xytron™ PPS and ForTii® PPA
offer best-in-class thermal resistance, as
well as excellent creep and thermal shock
resistance. Dedicated electro-friendly
compounds with a controlled ionic content
of less than 50ppm minimize the risk of
electro corrosion.
E-Motor Oil Distribution Ring
E-Powertrain System
As the EV market grows, demand for
high-quality e-drive lubricants is increasing.
Vehicle electrification trends are also
changing performance requirements for
e-motor oil distribution rings. As electric
motors and reduction gears that EVs use
become more compact, new energy efficiency,
heat removal and speed drive gear oil
formulation requirements need to be met.
Materials for oil distribution rings need to
retain more than 60% of their mechanical
performance after oil aging, high dimensional
stability and low warpage to minimize the risk
of oil leakage. Akulon® PA66, ForTii® PPA and
Xytron™ PPS provide these capabilities.
Sensors
Electrical and Electronics System
Sensors and microelectromechanical systems
(MEMS) are key components in many
electronic interfaces. They manage internal
and external controls and require materials
proven to meet the most stringent
performance requirements. Over-molded
components, including solenoids and sensors,
rely on advanced materials that withstand
extreme temperatures, and can be processed
at low pressure to avoid electronic component
displacement.
ADAS Housings and Brackets (i.e. Radar or Camera)
Connected Car System
To enable driver assistance functions, ADAS
housings need to be dimensionally stable, offer
high chemical and UV resistance, conduct high
thermal loads, and prevent signal interruptions.
Radomes for radar sensors need to show a high
level of RF transparency. Our advanced material
portfolio fulfills these requirements and prevents
electro corrosion in critical ADAS components
to lower the risk of safety system failures.
Dedicated laser-weldable PBT compounds support
low cycle times – reducing manufacturing
costs. Electrically conductive compounds enable
excellent EMI shielding above 50dB across the
entire frequency range, while providing thermal
conductivity of roughly 1W/mK to disperse heat
from hot spots.
FAKRA & HSD Connectors (corrosion-resistant)
Connected Car System
Connected cars are driving demand for
high-speed data (HSD) and FAKRA
connectors. As a vital link to the brain of the
vehicle, connectors link coaxial cables to
receivers and transceivers for
communications and entertainment systems.
Connectors also play a key role in passenger
safety. ForTii® Ace eliminates the risk of
FAKRA connectors blistering during reflow
assembly – even after long shelf times with
open bags of non-assemble connector rails
or resin bags. ForTii Ace is free of halides and
metallic ions to avoid the risk of electro
corrosion under constant DC bias for metals
in sensitive electronics.
Low Voltage Connectors
Electrical and Electronics System
Vehicles require safe and reliable connectors
to enable a growing number of critical active
safety and driver assistance systems. Akulon®,
Arnite®, EcoPaXX®, ForTii® and Stanyl® are
trusted materials for manufacturing
high-performance connectors for millions of
new vehicles.
Coolant Expansion Tank
Thermal Management System
In EVs, thermal management systems (TMS)
are critical to keeping battery packs within
the optimal temperature range – to ensure
EVs are safe and improve engine efficiency
and service lifetimes. XytronTM is ideal for
developing TMS components such as coolant
expansion tanks that require the highest
hydrolysis and heat aging resistance. ForTii®
PPA and EcoPaXX® PA410 also offer proven
performance in TMS components.