SABIC, a global leader in the chemicals industry, is spotlighting advanced material technologies and creative solutions for energy storage, particularly electric vehicle (EV) battery components and charging infrastructure, here at The Battery Show North America (Booth 4807). The company is displaying concepts and commercial applications that illustrate the value of its polymers and specialty thermoplastics for increasing design flexibility, improving safety and performance, streamlining manufacturing and enhancing sustainability.
Fahad Al-Harthi, global director, Automotive, SABIC, said “Important advancements in EV battery technology are being enabled by high-performance materials and innovative application approaches. SABIC invests in original research and development for energy storage solutions, and we also keep pace with the fast-changing requirements of the industry and individual customers. Our materials could make a significant contribution to solving emerging design, manufacturing and performance challenges.”
At The Battery Show, SABIC is exhibiting noteworthy applications and use cases that can provide both inspiration and practical design and manufacturing guidance.
- Multi-material EV battery pack enclosure: This novel enclosure, an alternative to an all-aluminum design, reduces weight by 20 percent. Its cover panel uses a thermoplastic / organosheet sandwich structure; its tray is made completely from thermoplastic; and its underbody panel is metal. Flame-retardant (FR) STAMAX™ long glass fiber polypropylene (LGF-PP) is used for the thermoplastic components.
- Thermoformable insulation film in EV battery packs: This film is based on chemically resistant NORYL™ NHP8000VT3 resin, which meets the UL94 V0 standard at 0.25 mm and achieves the highest comparative tracking index level (CTI-PLC0). These properties enable the insulation film to be used in higher-voltage (600V) EV batteries to help prevent ignition and resist breakdown. Sustainable versions of the film are available.
- DC-DC hybrid converter: Another multi-material example is this demonstrator, which features a plastic-metal hybrid. The lightweight plastic housing is made with ULTEM™ resin, while a stamped sheet metal insert provides thermal management of the printed circuit board. This approach may reduce manufacturing costs by up to 30 percent compared to an all-aluminum version. Most ULTEM resin grades can be requested as ISCC+ certified renewable versions.
- Polypropylene (PP) replaces polyamide (PA) bringing more safety and value: Replacing FR PA with intumescent FR PP in thermal runaway barriers, module housing, busbars, and other EV battery components could reduce weight and costs while equaling or surpassing PA’s fire safety performance. Samples at the booth show the potential of intumescent FR PP STAMAX resin to reduce cold side temperatures by ~100°C vs. FR PA.
- Cylindrical cell frames for EV battery protection: Made with LNP copolymers, these thin-wall cell frames deliver UL94 V0 compliance at 1.5 mm. Compared to polyamide (PA) frames, they offer improved dimensional stability thanks to lower moisture uptake and lower warpage. Also, they meet low-temperature ductility requirements with impact resistance down to -40°C. For sustainability, grades can be requested as ISCC+ certified renewable versions.
- Busbar insulation covers: Prototype EV busbars on display use SABIC’s FR PP resin and VALOX™ FR PBT resin for their insulation covers. These materials deliver outstanding fire safety (with PBT available to meet higher service temperature requirements) and superior arcing control and can be dyed orange for visibility and safety. The resins are formulated without intentionally adding per- and polyfluoroalkyl substances (PFAS) or halogen. Processing options include injection molding and extrusion. Compared to a traditional FR PA solution, use of SABIC’s PP resin can potentially offer up to 20 percent in cost savings and 10 percent in weight savings, while SABIC’s PBT resin can deliver reduced moisture absorption and improved dimensional stability.
- Nichicon capacitors for EV AC-DC traction inverters: In the first commercial application of ultra-thin ELCRES™ HTV150A dielectric film, Nichicon has developed high-temperature, high-voltage, commercial-quality capacitors for EV inverter modules. The film is the first in the industry to deliver stable performance at operating temperatures of -40°C to 150°C and frequencies up to 100 kHz.
- Charge Amps Dawn EV charger: The housing of the Charge Amps Dawn EV charger contains in the range of 50 percent certified renewable LEXAN™ polycarbonate from SABIC’s TRUCIRCLE™ portfolio, supporting the EV charger provider’s commitment to develop the circular bio-economy and help mitigate climate change issues.