MAKING ELECTRIC VEHICLES SAFER, LIGHTER AND MORE SUSTAINABLE
The future of mobility is rapidly changing. Automotive OEMs need advanced materials to address these dynamics.
Envalior’s unique portfolio of high-performance engineering materials enable OEMs to realize future-proof designs that make cars lighter, safer and more sustainable.
By selecting one of the tabs at the top of this illustration, you can explore how our materials can support manufacturers in making vehicles future-proof, by making them:
Safer
Lighter
More sustainable
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.
High Voltage 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. Unlike competing PAs that easily absorb moisture, our Pocan® solution offers a low moisture aborption, which solve the ion migration issues. 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 platforms ( >800V) 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 Pocan® 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 of Pocan® PBT, ForTii PPA and Xytron™ PPS 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. Durethan and 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. Xytron™ 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. Xytron™ 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. Xytron™ 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
Bearings used in hybrid and electric powertrains are required to withstand high rotational speeds, high centrifugal loads and high operating temperatures. Increasing power density trends in automotive only further increase these requirements. Bearings are also required to operate at low friction and high efficiency and need to cope with various lubricants and other chemical media common in automotive. Envalior offers material solutions that are able to meet these demands.
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.
Automotive 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.
Advanced Driver Assistance Systems (ADAS) Sensors
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. For a safe and durable fastening of ADAS sensors to the vehicle, materials with excellent mechanical properties are necessary. Therefor, Envalior offers various materials, e.g. Akulon® or Durethan® polyamides.
FAKRA & HSD Connectors
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®, Pocan® 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. ForTii® PPA and EcoPaXX® PA410 also offer proven performance in TMS components.
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.
