[chinaplas review] a roundup of innovative solutions for new energy vehicles: Electrification, Thermal Management, and Lightweighting
Core Competitiveness of New Energy Vehicles
Hidden in every precise component
Today, Xiangxiang will focus on
Three-electric system (battery, motor, and electronic control)
Thermal management system,
Lightweight, intelligent drivingand other trending topics
Exhibition Review ③: New Energy Vehicles
When it comes to new energy vehicles, the previous application was a transition from fuel vehicles to electric vehicles.
And at this year’s CHINAPLAS, it was directly felt on site that the technological trend is moving towardDeep Electrification + IntelligentizationExhibits such as LiDAR covers, camera brackets, power battery packs, and charging systems were all on display, with materials covering high-performance engineering plastics such as PC, PA, PPS, and PEEK.
BASF
BASF launches at the exhibition siteBrand new flame-retardant high-temperature polyamide Ultramid® FR HTPA。
This material has passed the -40 to 150°C × 1,000-cycle thermal shock test with no cracking; CTI is as high as 600 V; it features low density, improved surface quality, laser marking capability, and processing stability.
▲The new flame-retardant high-temperature polyamide Ultramid® FR HTPA provides a high-performance solution for metal insert injection-molded components in new energy vehicles.
also showcased its partnership withWeilan New EnergyJoint ReleaseAll-solid-state battery packThe battery pack uses BASF’s innovative material solutions, including engineering plastics (Ultramid® and Ultradur®) as well as polyurethane products (Elastolit®, Elastoflex®, Elastan®, and Eastocoat®), which help achieve...Vehicle weight reduction and thermal management optimizationand enhance the safety performance of electric vehicles (EVs).
▲ All-solid-state battery pack. (Image source: BASF)
▲Ultramid® (PA) is used in DC fast-charging gun heads. (Image source: BASF)
SABIC
At SABIC’s “Transportation” area, a range of innovative solutions related to electric vehicles were showcased.
Electric vehicle charging gun. UL94 V0 flame retardancy; excellent low-temperature mechanical properties, can pass low-temperature crushing and drop tests for charging guns; weather resistance meets UL746C F1 certification; excellent chemical resistance to grease and other chemicals; good processability; outstanding appearance.
Battery pack plasticization solution. STAMAX™ resin. Lightweight/substitute for metal; achieve functional integration; V0 flame retardant, UL94 V0 @ 1.5 mm.
LG Chem
LG Chem is showcasing new high-performance material solutions related to batteries, including above.High-performance anode binderwith excellent electrical conductivity and dispersibilityCarbon nanotube (CNT)A new generation based on aerogel manufacturing.Thermal Insulation Material Nexula®
▲CNT powder
▲ Nexula® Aerogel Insulation Material
also demonstrated the use ofUltra-high polymerization degree PVC HRTP4000 materialThe charging cable has improved flexibility by approximately 30% compared to existing materials, significantly enhancing the product's flexibility and convenience. The HRTP series is suitable for flexible cables with various charging interfaces.
▲ Innovative flame-retardant protection technology for electric vehicle batteries.
Shisuoke
Syensqo focuses on showcasing its inElectric Drive System and Thermal Management Systemmaterial solutions.
Newly launchedAmodel® PPA HFFR-4130 BK324Specially designed for the new generation of integrated systemsElectric drive system busbarDesigned with excellent thermal shock resistance and ATF corrosion resistance, and compliant with the UL94 V-0 flame retardant standard.
▲ Photo taken at the Shisuo Ke Expo booth.
▲KetaSpire® PEEK: Magnet wire insulation and slot liner solutions designed for oil-cooled motor systems above 800V.
Amodel® PPA and KetaSpire® PEEK are used in electronic oil pump rotors. Ryton® PPS is used in electronic oil pump motor stators and rotors.
Ryton® PPS is used in thermal management modules.
Solef® PVDF, as an advanced positive electrode binder, provides excellent adhesion for batteries; as a separator coating, it enhances the cycle life of the battery. Energain®, as an electrolyte solvent, helps the battery achieve higher energy density and better performance.
▲ Syensqo inverter material solutions. Ryton® PPS material offers excellent linear coefficient of thermal expansion performance and resistance to cracking under thermal shock, making it especially suitable for overmolding designs with metal inserts.
In the field of new energy vehicles, EvonikVESTAMID® PA12materials, with excellent chemical resistance and high-temperature resistance, are widely used inBattery cooling pipeline, power busbar, and energy storage system.Meeting the requirements for efficient heat dissipation and long-term stable operation.
VESTAMID® PA12 is used in the thermal management piping system of new energy vehicles.
▲VESTAMID® cooling tubes. Multilayer tubes made of VESTAMID® PA12 are significantly lighter than conventional rubber or metal tubes. At the same time, PA12 flexible tubes reduce wall thickness, decreasing the overall tube volume while maintaining the same inner diameter. Thermoplastic PA12 cooling tubes can be assembled with quick connectors, are easy to bend, require no clamps, and save space inside the battery pack.
Evonik also focused on showcasing.VESTAKEEP® PEEK materialApplications in core components such as automotive motors and transmissions.
▲ Flat wire made from VESTAKEEP® PEEK offers excellent dielectric and mechanical properties, as well as heat and chemical corrosion resistance, making it suitable for various winding methods, including high-voltage motor platforms. (Image source: Automotive & Parts AP)
Daicel Group
The Daicel Engineering Plastics booth showcased the above content.Sensor materials for intelligent driving, high-performance PPS for electric drive systems, PBT for battery modules with resistance to thermal shock, and LCP for high-voltage connectors
The photo was taken at the booth of the Dacelo Engineering Plastics Exhibition.
On the exhibition stand.Vehicle Material Distribution ModelIt directly illustrates the application locations of engineering plastics in power batteries, motor systems, high-voltage connectors, radomes, and charging systems.
Sinochem International
Sinochem International brought StarAir® Modified Foamed PPE for New Energy Vehicle BatteriesThis material achieves a UL94 V-0 (3 mm) flame-retardant rating, combining high mechanical strength with excellent impact resistance to comprehensively enhance battery pack safety and range performance, and can be used forPower battery casing, cell bracket, insulation board, BMS shelland other key components.
It also shows##PPE, PA66, and PBT materialsfor use inBattery casing, end plate, separatorand other components, meeting the stringent requirements of battery systems in the new energy vehicle and energy storage sectors.
▲ New energy vehicle onboard battery bead foam products.
Jinyang showcases material solutions covering all scenarios for interior and exterior trim, power systems, intelligent cockpits, three-electric systems, and thermal management.
Flame-retardant PA66, high CTI flame-retardant PBT, and flame-retardant PC+ABS alloy. Charging Gun Head, High-Voltage Connector, CCS BracketProvides reliable high-insulation and flame-retardant protection for key components.
Reinforced PBT and PA66Applicable toIn-vehicle cameras, radar modules, EGR valvesPrecision sensing and execution components, comprehensively supporting the upgrade of new energy vehicles toward higher performance and greater intelligence.
▲ Vehicle-mounted radar module assembly
Enhanced PBT Series
▲ Sensor housing
Reinforced PA66 Series
Yizumi
Yizumi Live Dynamic DemonstrationThermoplastic Composite Automotive Lightweighting Molding Solutions。
The scheme is based on thermoplastic composites, usingInjection Molding One-Step ProcessIt can shorten the manufacturing cycle by 30% to 50%, achieve a weight reduction of 20% to 30% compared to traditional steel, and also offer high design freedom and structural strength.
▲ Product: automotive door side-impact beam, material: PP + 30% GF. (Image source: YIZUMI)
KraussMaffei
The KraussMaffei GX650 injection molding machine, equipped with the RimStar metering system, was demonstrated on-site.ColorForm In-Mold Coating Technology Integrated forming of the B-pillar for new energy vehiclesapplications in the field.
The GX650 integrates GearX ultra-fast mold clamping (0.25 seconds), high-pressure cylinder rapid pressure build-up (0.35 seconds), and single-cylinder injection accuracy of ±0.1%, among other leading technologies, enabling one-shot molding to achieve...Scratch-resistant, self-healingThe high-quality surface eliminates the need for subsequent spray coating processes, reducing carbon emissions and pollutant discharges while significantly enhancing production efficiency.
▲Image source: KraussMaffei
At the Bochuang exhibition booth, the BU600-EV was demonstrated live on site.Precision Injection Molding of New Energy Vehicle Lamp Coversprocess. This model is a large two-platen electric injection molding machine developed by Borch specifically for large, high-precision automotive components.
▲ Image source: Bochuang
The applications of the BU600-EV go beyond vehicle lighting; it is also widely used in various key components of new energy vehicles.Lighting system(LED lens, lamp housing, light guide strip)Interior and exterior trim parts(Large grilles, instrument panel, door panel inserts)Three-electric system(Battery Pack Upper Cover, Motor End Cover)Structural and functional components(Air ducts, brackets, connectors).
Teder has made a major breakthrough in the injection molding of automotive lighting components.ColorSure™ In-Mold Coating Process。
Image source: Terry
This process efficiently integrates injection molding with surface coating, overcoming the pain points of traditional secondary spraying processes, such as complexity, long cycles, high VOC emissions, and insufficient adhesion. At the same time, by incorporating PUR polyurethane coatings, it endows products with excellent scratch resistance, self-repairing properties, and higher surface smoothness and gloss, providing a more aesthetically pleasing and environmentally friendly integrated manufacturing solution for intelligent visual systems and high-gloss exterior components in new energy vehicles.
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Let’s immerse ourselves in viewing the pictures~
▲ Millimeter-wave radar absorbing bracket. Absorbing material. Absorbs electromagnetic waves, reducing interference and false alarms.
Radar cover. PC/PET material.
▲ Radar cover plate. High rigidity; dimensional stability; coating stability (chemical resistance); excellent surface quality.
Millimeter-wave radar sensor
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