The global plastic for the electric vehicle market is projected to reach around USD 2,620 million by 2025. The stringent emission norms and demand for weight reduction in electric vehicles requires polymer solutions meeting these customized performance requirements, especially for the interior application segment.
Customised Polymer Solutions
The main reason for high-performance polymer compounds is stringent emission standards to drive electrification as well as Weight Reduction. Another important aim is OEM preferences for thermally stable engineering plastics.
Reduced Weight and Cost
The main reason for OEMs to choose metal-to-plastic conversion and injection molded plastic components is weight reduction. Lighter-weight electric vehicles have a greater range between recharges, which is a major consideration for customers while making a new purchase. Also, light-weighting vehicles (both battery-powered and conventional) simplifies compliance with increasingly stringent governmental regulations surrounding fuel efficiency and reduced reliance on natural resources. Injection molded plastic parts are generally less expensive to produce than metal components, which allows OEMs and electric vehicle makers they serve to better control costs, maximizing profits.
Injection molded plastic parts can be made using materials with characteristics that address certain, requirements unique to electric vehicles. Batteries, for example, must remain cool. The number of Formulated Polymers Limited engineering plastics compounds offer excellent heat resistance from which to construct battery compartments and cooling systems without sacrificing durability and safety.
Strength and Safety
There’s sometimes pushback with regards to safety and mechanical performance. FPL’s range of Formpoly reinforced FORMPOLY & STARFLAM compounds engineered to rival or exceed metal’s tensile strength while also offering exceptional modulus, fatigue, creep resistance and impact resistance while cutting weight by around 30%.
Engineering Plastics For Battery Applications
FPL has developed engineering thermoplastic, solutions for battery pack designs with its flame retardant low-density thermoplastic materials that target battery pack requirements, in particular:
- UL94 V0 flammability rating at a minimum thickness (0.8 mm)
- Chemical resistance testing to coolants and electrolytes
- Adhesive compatibility for ease of assembly and part integration
- High specific strength, stiffness, and superior impact properties for outer housings applications.
FPL is drawing upon its expertise in engineering compounds and has designed polymer solution to produce lighter Flame Retardant reinforced grades with superior impact performance. FPL is also developing solutions in Polyamides, ABS blends, PPE compounds and polypropylene (PP) grades from its portfolio, which show promising applicability.
Use of FORMPOLY mPPE COMPOUNDS resin can also help automakers avoid the use of chlorinated and brominated FR materials, providing a potential environmental benefit. FORMPOLY & STARFLAM flame retardant compounds in PA6, PA66, PPS, ABS compounds are used in EV battery applications due to their superior mechanical performance at lower thicknesses and shorter cycle times.