In this blog post I cover six areas which deal
with the increasing importance of plastics for Electric Vehicles (EVs) and
autonomous driving starting from 2020.
Table 1: overview of key focus areas for plastics in EVs and autonomous driving |
Let us walk through all the six areas:
Light-weighting – range extension and efficiency
for electric cars
Light-weighting
plays in several areas of the EV an importance and aims to provide smaller and
lighter components. In a standard internal combustion engine car, plastics represent over 50% of the volume, however only 10% of the car weight. The battery pack is the heaviest part of the
whole electric car and plastics light-weighting solutions have the potential to
lower the overall weight situation. Current battery housings are made using an aluminum
cast solution [1]. Furthermore, battery housings need to fulfill several
requirements such as crash protection, battery cooling and ease of maintenance.
Thermoset based composites, as well as step by step thermoplastic composites
show potential to replace aluminum castings and fulfill the afore mentioned requirements.
Amorphous materials for sensors and LEDs
LED-based lighting technology is already state of the art in cars and it offers many possibilities for the design and functionality of classic front and rear lamp applications. There are already diffractive seamless lens structures which integrate a holographic film into a polycarbonate rear-end structure. Ongoing is the integration of electronics and driving sensors such as LiDAR and radars into one operating unit. The integration of LiDAR systems into invisible components is achieved by using black-panel-based polycarbonate color technology. This solution guarantees the highest IR transmission based on the required IR laser wavelength. Polycarbonate will play a key role for so-called people mover which have large transparent structures. Realizing these structures can be done via the polycarbonate glazing technology (360° glazing concepts).
Electroactive Polymers
In a previous post I highlighted already the importance of electroactive polymers. Polyvinylidene fluoride (PVDF) has piezoelectric as well as ferroelectric properties which can be used to make car speaker systems. The integration of vibrating surfaces all over the car (dashboard; turning headrests into resonating chambers) evolves the car into an entertainment center. Piezoelectric polylactic acid is another potential material solution for such new applications.
System integration
Injection
moulding allows the production of complex geometries. Furthermore, system
function integration with engineering polymers (e.g. integration of damping
elements for noise and vibration reduction) will further reduce costs and weight
in electric cars. Metal replacement of transmission housings of electric cars
are an example for integration of different materials and technologies: local
reinforcement is achieved by thermoplastic composite tapes (unidirectional
tapes based on PPA or PPS with carbon fiber) and overmoulded with short fiber
reinforced PPA or PPS. Since transmission and power electronic housings need to
have EMI shielding, placing the tapes in a 0° and 90° orientation will lead to
a filtering effect and as a consequence EMI shielding can be achieved. Another
integration field is the two component moulding using a hard component (PA,
ASA, POM) and combining it with a soft component (thermoplastic elastomer). In
particular for sealing of power electronic parts and housings in electric cars,
two component solutions where a flame retardant TPE is moulded on a flame
retardant PP are already existing.
Interpolymer substitution and recycling
In several
areas of the internal combustion engine (ICE) car, replacement of established
plastics takes place. This trend will continue in electric cars as well.
Polypropylene blended with polystyrene is replacing ABS in interior decorative
parts. Another example is polyketone. It is an engineering polymer which shows
higher heat performance compared to polyamide 6 and 6.6. Polyketone has
excellent wear resistance and impact strength, outperforming POM. Furthermore,
they have a low moisture absorption (similar to PBT) and have an excellent
chemical resistance, in particular toward automotive fluids, hydrocarbon
solvents and salts. Commercially it is attractive to replace aliphatic
polyamides, POM and PBT in the automotive market, as well as other markets.
Future aim of the automotive industry is to minimize the amount of different
grades and simplify the polymer chemistries in electric cars. This will
accelerate recycling efforts and re-usability. Key focus area is the recycling
of the battery chemistry and polymers used for making cathode and anode
binders.
Battery
materials
Here,
different polymers play a role for developing improved lithium-ion battery
systems by optimizing the binder materials for anode and cathode (PVDF basis)
and to develop robust solid-state batteries. Solid-state batteries will allow the
customer to recharge the battery in a short period of time and offer more mileage
range too. Furthermore, metal replacement of battery housings and module parts
will continue, as already highlighted in section one. Engineering polymers are
more and more used as battery module separators and end plates.
How
electrification influences plastics manufacturing
The next
five years will show an increase of plastics demand from the automotive
industry. Demand increase will be seen in certain polymer types, combined with
application focus. Polyolefins such as polypropylene will grow due to expanding
exterior and interior applications. Also, thermal conditions are much lower in
electric cars (60-80°C) allowing polypropylene to replace engineering polymers,
as well as engineering polymers replacing high heat polymers in certain areas.
Higher
growth rates are expected in the Asia-Pacific regions compared to established
automotive markets. Focus on innovation will allow manufacturers to meet the
upcoming application requirements. Also focus will be on the establishment of a
circular economy and structured recycling.
Thank
you for reading and #findoutaboutplastics
Greetings,
Herwig
Juster
Literature
[1] https://www.spotlightmetal.com/solutions-for-ev-battery-housing-at-euroguss-2020-a-900422/
[2] https://www.composites.media/the-future-of-thermoplastics/
[3] G. Pilz, et al. : Dynamic Mechanical Profile of Polyketone Compared to Conventional Technical Plastics, AIP Conference Proceedings 1779, 070008 (2016); https://doi.org/10.1063/1.4965540
[4] http://www.poketone.com/en/applications/automotive_index.do
[5] https://www.kraiburg-tpe.com/en/flame-retardant-tpe-electrical-sector
[6] https://www.solvay.com/en/article/future-of-mobility-is-light?utm_medium=social&utm_source=linkedin&utm_campaign=Stories+or+Medium&utm_content=100001741732062&linkId=100000034561877
[7] https://doi.org/10.3144/expresspolymlett.2021.25
The primary reason advanced materials such as polymers are used to support the body of cars is that they're lightweight. Polymer composites directly reduce the overall weight of a vehicle, and lighter vehicles move faster with less propulsion energy expended.chinohillsford.com
ReplyDeleteThis comment has been removed by the author.
ReplyDeleteEmmbros Autocomp Limited is recognized as one of the reputed Indian organizations as the supplier, exporter and manufacturer offer an extensive variety of engineered products which includes Front Axle Shafts, Rear Axle Shafts and Universal Joints Differential Housings etc. the company manufacture these products of electrical machine parts using quality raw material and advance technology.
ReplyDeleteWe are one of the biggest suppliers of automotive products in Badi HP. We export our quality products to the top countries of the world mostly to American and Indonesian markets. Our clients are highly satisfied with our products. Our core competency is our supreme quality and on-time delivery.
ReplyDeleteThis article is both informative and entertaining.
ReplyDelete