Advancements in plastics pivotal to transport electrification
- PostedPublished 21 September 2024
In the rapidly evolving world of battery electric vehicles (BEVs), the need for innovative materials is growing due to the unique challenges faced in thermal, electromagnetic and acoustic shielding.

Chemical companies are busy developing new grades of specialised plastics to capture these opportunities.
Durability
Unlike internal combustion engine (ICE) vehicles that generate waste heat only while running, BEVs often require their thermal management systems to run even when stationary due to regular charging, temperature regulation, and battery preconditioning.

As such, materials used in BEVs must maintain their properties and performance for longer periods, so materials previously tested for 3000 hours in ICE vehicles are now being tested for 5000–10,000 hours in BEVs.
Texas-based firm Ascend Performance Materials (APM) has developed long-chain polyamides called HiDura PA610 and 612 to meet the increasing demand for highly chemical-resistant materials in coolant circulation tubes and battery seals.

APM HiDura business manager Kaan Gunes said these resins and engineered plastics have “exceptional ductility, UV weatherability and hydrolysis resistance” that delivers “reliable, long-term performance in some of the harshest conditions”.
“The various grades we developed are designed to improve the reliability of our customers’ products.”
Fire resistance
To prevent thermal runaway and electric arcs, materials used in battery packs and charging equipment must be designed with flame retardant qualities.

While conventional materials like polycarbonate, polyesters, and acrylonitrile butadiene styrene can be made flame-resistant, they may not offer the same level of flame-retardant properties as advanced polyamide or nylon options.
APM’s flame-retardant PA66 material, called Starflam X-Protect, is reinforced with glass fibres and was developed for injection-moulded applications.
It is claimed to withstand direct flame exposure at 1100°C for 15 minutes, providing sufficient time for passengers to escape in the event of a fire, making it suitable for BEVs and other safety-critical applications.
Rapid charging
As the demand for faster charging times continues to rise, there is an increasing need for reliable materials that can withstand higher voltages.

Recognising this requirement, Belgian multinational chemical company Solvay has developed a new grade of polyphenyl sulphide (PPS) it calls Ryton Supreme HV, for high-voltage applications.
It meets the industry standard of 600 volts and offers improved heat resistance with a rating of over 175°C. This makes it suitable for power electronic housings and chip carriers.

Solvay Materials head of automotive marketing Brian Baleno said “OEMs and Tier 1 suppliers in automotive are constantly seeking ways to improve safety, reliability and sustainability without compromising system cost efficiency”.
“We constantly work with our customers to find solutions to their challenges, leveraging the potential of our materials portfolio and our expertise to bring new innovations to life.”
Electromagnetic shielding
Plastics for BEVs are not only being developed to manage heat but also to replace metal shielding for electromagnetic and radio frequency interference.

Thermoplastic compounds like carbon fibre, nickel-coated carbon fibre, or stainless steel fibre are used as conductive fillers in these plastics.
Unlike metal shielding methods that reflect radio frequency and electromagnetic and radio frequency interference, these materials are embedded in the plastic, reducing cost as well as improving battery range due to weight savings.
Acoustics
In contrast to ICE vehicles, BEVs need specialised materials to mask noises produced by motor and compressor vibrations, which can reach high frequencies up to 4000Hz, ten times higher than those generated by a combustion engine.

APM has designed a nylon-based material it calls Vydyne AVS that serves as an alternative to polyurethane foam and incorporates chassis-mounted brackets engineered to conceal these high frequencies.
- CategoriesIn SightGlass
- Tagselectric vehicles, EV, Hybrid, plastics, plug-in hybrid, SightGlass News Issue 33, thermal management