As the world transitions toward electric vehicles (EVs), the pace of adoption varies significantly across regions. Despite regulatory hurdles in the United States, globally, EVs are on the rise, capturing over 20% of new car sales in 2024. The International Energy Agency forecasts this to increase to 25% in 2025, with China potentially reaching a staggering 60% due to decreasing prices.
Compared to traditional combustion vehicles, EVs have fewer parts, but they face unique demands, particularly in high-power systems that require advanced insulation and heat dissipation solutions.
Innovations in EV Platform Design
The shift from internal combustion to electric vehicles isn’t just about changing the power source; it’s a complete transformation of vehicle design. Many manufacturers are adopting 800-volt battery systems, a step up from the traditional 400 volts. This evolution is not only about increasing the efficiency and speed of charging but also about challenging material producers to develop components that can withstand the new demands.
High Voltage and Material Challenges
The 800-volt systems, introduced by Porsche Taycan in 2019, are now being integrated into mainstream models like the 2025 Hyundai Ioniq 5 and Kia EV5. “Consumers’ biggest concern is range. Fast charging helps address that concern because instead of charging for hours at a time, you’re charging for minutes,” says Brian Baleno of Syensqo. To meet this need, materials must exhibit high dielectric strength and a high tracking index.
Hyundai’s Ioniq 5 supports fast charging with its 800-volt architecture. Source: Hyundai Motor
At these high voltages, insulation materials are critical to prevent short circuits and maintain safety. The dielectric strength and comparative tracking index (CTI) of these materials are essential to ensure reliability and safety against potential electrical failures.
Motor Insulation for EVs
With higher voltage systems, every component in the drivetrain, including motors, must endure increased electrical and thermal stresses. For instance, Volvo’s new 800-volt platform utilizes Syensqo’s Ketaspire PEEK for motor insulation, offering superior temperature stability and chemical resistance.
Syensqo PEEK materials are utilized for motor winding insulation. Source: Syensqo
Addressing Thermal Shock
Busbars are crucial for connecting the various elements within an EV’s drivetrain. These components, overmolded with plastic for insulation, must endure rapid temperature changes without cracking. Celanese has developed glass-filled polyamide materials like Zytel HTN, specifically designed to withstand these conditions.
Busbars using Celanese’s Zytel HTN are designed for thermal shock resistance. Source: Celanese
Innovative Battery Pack Designs
In the quest for more compact and efficient designs, automakers are integrating battery packs into vehicle floors. The Cadillac Celestiq, for example, employs a unique battery pack design using a polyamide compound from SABIC to ensure effective thermal management and structural support.
The Cadillac Celestiq utilizes a polyamide compound for its battery module cover. Source: Society of Plastics Engineers
Enhancing Charging Infrastructure
For EV owners, access to fast charging stations is crucial. However, currently, only a small percentage of public stations offer 350 kW or higher. Durable, weather-resistant charging systems are essential, requiring advanced plastics like Envalior’s new PBT grade, Pocan BFN4232ZHR, which balances numerous properties for optimal performance.
Original Story at www.ptonline.com