Range Extender Technology Embraces Innovation! SAIC-GM Challenges Li Auto and AITO, New Opportunities for Plastics Emerge

In the specialized plastic world, observations on August 12 found that recently...In the 398th batch of the "Announcement on Road Motor Vehicle Manufacturers and Products" released by the Ministry of Industry and Information Technology, the debut of models such as the XPeng X9 Extended-Range Version and the GAC Aion i60 Extended-Range Version marks that both emerging forces and traditional automakers are heavily investing in the extended-range sector. Amid this technological revolution, the "Zhenlong" (True Dragon) extended-range system launched by SAIC General Motors Pan Asia Technical Automotive Center has undoubtedly set a new benchmark for extended-range technology and brought unprecedented development opportunities for related plastic materials.

Extended-range technology"Four Major Pain Points" and Market Desires

Since the range extender technology was introduced, it has been accompanied by numerous controversies. From ideals to the general public...From the "technology debate," to Great Wall Motors' firm stance of "resolutely not making range extenders," and then to NIO founder William Li's recognition of the market potential of range extender technology and his "transition theory," range extender technology has always been at the center of public discussion. Industry experts point out that compared with plug-in hybrids, range extender technology has relatively singular functionality, higher fuel consumption, and suffers from four major pain points: reduced power in low battery state, short pure electric range, rapid battery degradation, and significant noise when the range extender engages.

However, the market’s desire for anxiety-free mileage technology has allowed range extender technology to maintain strong vitality. Professor Ma Jing from Chang’an University represents the industry consensus: range-extended vehicles possess the environmental protection and power advantages of pure electric vehicles, while also having the range advantage of traditional internal combustion engines, making them more favored by consumers. With the success of range-extended models from companies like Li Auto and AITO, and the strong momentum from emerging brands such as Avatr, IM Motors, and Xpeng, range-extended vehicles are set to have a promising future.It will become an important market segment within the next 3-5 years.

"Zhenlong" Range-Extended System: Technological Innovation, Pain Point Resolution

Facing range-extending technology"Four major pain points," SAIC-GM Automotive Pan Asia Technical Automotive Center has provided its own solution with the "Zhenlong" range-extending system. As the pioneer of range-extending technology, SAIC-GM Automotive, with seventeen years of technical accumulation, has redefined the range-extending experience with the "Zhenlong" range-extending system.

No power loss when the battery is low, delivering consistently strong performance.

The "True Dragon" range extension system, designed and developed with top-tier hardware standards, addresses the issue of power reduction in low battery conditions. The Zijing L7 is equipped with a single motor boasting a power output of up to 252kW and a maximum speed exceeding 22,000 rpm. This is complemented by the Ultium 2.0 high-performance battery specifically designed for hybrid systems, ensuring strong output even in low battery conditions. Tests show that the difference in 0-100 km/h acceleration time between full and low battery states for the Zijing L7 is less than 0.1 seconds, achieving an almost seamless transition of "full-to-low battery seamless integration."

Source: SAIC General Motors Buick

Long pure electric range, say goodbye to range anxiety.

To address the issue of short pure electric driving range,The "True Dragon" range extension system fully considers real-world scenario needs. The Zhijing L7 boasts the longest pure electric range of 302km in its class (CLTC), and with a 40.2kWh Ultium battery and 130kW fast charging technology, it achieves an efficient experience of "18 minutes to recharge 50%". Even on long-distance trips, the Zhijing L7's 59L large fuel tank and efficient energy consumption management ensure a fuel consumption of only 5.9L per 100km when the battery is depleted, which is over 15% more energy-efficient than mainstream products in the same class.

3. Long battery life and high safety performance

The "Zhenlong" range extension system establishes the industry's most stringent testing standard, PRC06 Pan-Asia development conditions, focusing on five key dimensions including average vehicle speed, high-speed ratio, and fast charging usage ratio, to define the assessment boundaries for battery cells, resulting in a 40% increase in battery lifespan. At the same time, it adopts a dedicated cathode formula and a structure that reduces internal resistance, having completed over 2,000 hours of full-temperature charging and discharging tests to ensure battery safety performance under extreme conditions. Ultimately, the "Zhenlong" extended-range hybrid battery achieves low degradation over 640,000 kilometers (CLTC) of pure electric range, setting a new standard for battery durability and safety.

The range extender engages seamlessly, maintaining the original tranquility.

Regarding the issue of loud noise when the range extender is engaged,The "Zhenlong" range extender system reduces noise at the source through precise control of a high-efficiency combustion system and the use of a specially thickened cylinder block designed for range extender applications, resulting in an overall engine noise reduction of 1.6dB. Additionally, the system adopts a coaxial integrated design for the generator and engine, reducing vibration during the start-stop process of the range extender system. In terms of the electric motor, a 72-slot motor and AI optimization technology are used, further reducing electromagnetic noise by 3dB compared to mainstream competitors. As a result, the "Zhenlong" range extender system achieves engine intervention noise of less than 0.5dB and steering wheel vibration acceleration of less than 0.04g, delivering a virtually imperceptible transition when the range extender engages.

Plastic Materials: The Unsung Hero of Extended-Range Technology Innovation

The success of the "Zhenlong" range extension system lies not only in its technological innovation and breakthroughs, but also in its in-depth exploration and application of materials science. In the electric drive system, battery system, power supply system, and thermal management system, special engineering plastics play an indispensable role.

Electric drive system: Insulation is wear-resistant and resistant to chemical corrosion.

The electric drive system has extremely high requirements for material insulation, wear resistance, and chemical corrosion resistance.PPS (Polyphenylene Sulfide) is used in components such as AC/DC busbars, featuring high flame retardancy (UL94 V-0), high temperature resistance (260°C for long-term use), and resistance to antifreeze corrosion. Injection molding ensures structural stability through integral forming. PEEK (Polyether Ether Ketone) is applied in motor slot insulation systems, with a dielectric strength of 190 kV/mm and stable dielectric loss at high temperatures. It replaces traditional epoxy resin, reducing weight by 40% and lowering noise by 5 - 8 dB. PI (Polyimide) is used for insulation layers in high-voltage connectors, with high temperature resistance (300°C) and high CTI (≥600V), suitable for 800V - 1000V platforms, integrating advanced communication technology. LCP (Liquid Crystal Polymer) is used for high-voltage connector bodies; after glass fiber reinforcement, arc resistance life is extended by 2 to 3 times, heat distortion temperature exceeds 300°C, and it is resistant to UV and humidity aging. PSF (Polysulfone) is used for insulating sleeves, featuring high dimensional stability and chemical corrosion resistance, suitable for metal insert overmolding processes.

Battery system: Insulation and flame retardant, ensuring high strength

The battery system requires materials with insulation, flame retardancy, and high strength properties.PPS is used for explosion-proof battery cover pole gaskets and other components; its weak conductivity ensures stable resistance, high-temperature venting, and low warpage, making it suitable for precision parts. PEEK is used for battery management system (BMS) housings and similar applications, offering a specific strength of 45 MPa·cm³/g and excellent dimensional stability (thermal expansion coefficient of 3×10⁻⁵/°C), supporting CTP technology and enabling a 19% weight reduction. PI is used for lithium battery separators, offering high-temperature resistance up to 300°C, high porosity, and excellent electrolyte wettability, thereby enhancing fast-charging performance and safety. LCP is used for battery module boards; the Xydar G-330 HH grade maintains insulation at 400°C, requires no halogen flame retardants, and its high flowability enables thin-wall design. PSF is used for battery case housings, providing flame retardancy (V-0 rating), chemical resistance, low smoke toxicity, and compliance with aerospace safety standards.

Source: LANXESS

Power System: Integrated High Power, Multifunctional Implementation

The power supply system pursues integration, high power, and multifunctionality, which imposes stringent requirements on materials.PPS is used for on-board chargers (OBC) busbars, etc., featuring high CTI (≥600V) and high voltage pulse resistance, suitable for 800V platforms. PEEK is used for on-board DC/DC converter insulation frameworks, with laser direct structuring (LDS) enabling three-dimensional circuit integration, reducing weight by 60% and increasing power density. PI is used for power management chips, etc., with 1700V GaN technology improving efficiency by 10% and single-chip multi-output reducing system costs by 20% - 30%. LCP is used for high-voltage distribution box connectors, with glass fiber reinforced arc resistance, suitable for 1200V ultra-high voltage platforms. PSF is used for transformer insulation components, with stable dielectric performance under high frequencies and resistance to corona aging.

Thermal management system: chemical corrosion resistance, dimensional stability

The thermal management system requires materials that are chemically resistant, dimensionally stable, and compatible with metal inserts.PPS is used for electronic water pump housings and other applications, offering hydrolysis resistance/antifreeze corrosion resistance, high weld line strength, and integrated injection molding. PEEK is used for liquid cooling plate thermal conduction layers, with a thermal conductivity of 15W/(m·K) after boron nitride filling, optimizing in-plane anisotropic thermal management. PI is used for PTC heater insulation layers, resistant to high temperatures up to 300℃, providing flame retardant insulation for escape time during thermal runaway. LCP is used for expansion tank interfaces, with excellent metal insert overmolding properties, resistant to ethanol/oil corrosion. PSF is used for compressor housings, with dimensional stability of ±0.5%, strong bonding with aluminum materials, catering to lightweight requirements.

The release of the "True Dragon" range extender system not only sets a new benchmark for range extender technology but also brings unprecedented development opportunities for related plastic materials. In the thriving new energy vehicle industry today, special engineering plastics, with their excellent performance and broad application prospects, are gradually becoming a key driving force for industry advancement. In the future, with the continuous innovation and popularization of range extender technology, plastic materials will play an increasingly important role in the field of new energy vehicles, jointly ushering in a new era of range extender technology.