Electric Vehicle Battery Systems

As demand for Electric Vehicles (EV) continues to grow, so does the demand for more robust and efficient batteries. Entire vehicle platforms are being built around the battery, which not only supplies power but also serves as a critical structural element in EVs today.

Both battery manufacturers and automakers are focusing on building lighter, more cost-effective batteries that can operate in a compressed space and charge quickly and safely. As the designs of these battery systems evolve, so do the needs and challenges of each component that make it all possible.

From the high strength and stiffness required in the battery’s enclosures and modules to addressing the demanding heat and flame resistance needed across a variety of components, polymers play an important role.

From thermoplastic resins and compounds to thermoset composite solutions, the diverse polymer portfolio from LyondellBasell is uniquely positioned to address your challenges in EV battery systems.

Material Solutions for EV Battery Systems

Battery Enclosures

Premi-SMC ? Hostacom ? Polyflam

Premi-SMC (Sheet Molding Compounds) are a lighter-weight alternative to traditional metals used in EV battery trays and covers. The high strength and stiffness of these lightweight composites offer flexibility for complex 3D designs that can meet structural, heat and flame requirements. When compression molded, cost efficiencies can be achieved when factoring in the life and output of a vehicle program. Polyflam and Hostacom polypropylene (PP) compounds can be considered for injection molding of higher volume components.

Battery Modules

Hostacom ? Hostalen ? Schulamid ? Schulablend ? Dura-BMC

Hostacom PP compounds can be tailored for high rigidity, excellent impact strength, superior dimensional stability, and high flow for thin wall housing and frame designs. Hostalen unfilled PP grades have also been used in module dividers and heat exchanger parts. For components requiring higher strength and stiffness at elevated temperatures, Schulamid (PA) and Schulablend (PC/ABS) products may be considered.?

Thermal Management

Schulamid ? Hostacom ? Pro-fax

Lower operating temperatures and pressures within EVs allow lighter weight cooling tubes extruded with Schulamid polyamide (outer layer) and Hostacom PP compounds and Pro-fax PP (inner layer) to meet requirements with lower cost. For tube connectors and manifolds, glass-reinforced injection molding grades can meet specifications for mechanical burst strength, resistance to abrasion, creep, and coolant fluids, along with matching coefficient of thermal expansion (CTE) for high quality assemblies.?

Electrical Systems

Schulamid ? Schuladur ? Polyflam ? Dura-BMC ? Petrothene

From housings and connectors to wire insulation, the EV electrical network has a set of demanding requirements. Schulamid grades can achieve UL ratings for flame, address thermal aging (RTI), and electrical performance. For extreme heat and flame areas, such as terminal blocks, Dura-BMC composites offer integrity to protect sensitive electronics. For wire harnesses, Petrothene polyolefin meets industry regulations for high voltage wire & cable insulation.

Download PDF | Automotive Solutions | Charge Port Assembly | Contact Us