ELECTRIC VEHICLE BATTERY PACKS

To support the ‘electrification revolution,’ there exists a growing need for specialty materials to realize the potential of energy storage technologies such as Li-ion batteries.

Our teams of dedicated experts work closely with our customers to tailor unique offerings that bring high standards of safety, functionality and performance.

Our computer assisted engineering (CAE) team is here to assist you throughout every step of your journey, from design concepts all the way through to the completed product.

SABIC’s Specialties business offers a number of materials for use in electric vehicle (EV) battery packs that can bring:

• Weight reduction
• Fire safety
• Thermal management
• Crash safety
• Design freedom
• Enhanced processing
• Lower system cost

Our Specialties portfolio of materials can assist our customers in adressing the rigors of regulations and standards for traction motor battery packs, including UNECE R100, UL2580, GB/T 31467.3 and SAE J2929.

Electric vehicle safety is of unparalleled importance. In lieu of universal regulations for electric vehicle battery modules and packs, a number of stringent safety regulations and standards exist across the globe. While the robust vehicle exterior affords protection to the battery pack, the battery pack and its contents face the very real possibility of damage in the event of collisions, or even through falls during assembly and maintenance. As a result, electric vehicle battery modules and packs must undergo a series of rigorous tests including crush, drop, exposure to fire, immersion and short circuit.

SABIC’s Specialties business offers a range of solutions with safety and functionality in mind. Our experts have a longstanding tradition of tailoring specialty solutions to meet demanding requirements, including those of electric vehicle battery packs. Whether these requirements are high impact strength and stiffness, electrical insulation or dimensional stability, or other specialty functionalities including non-chlorinated/brominated flame retardancy, electromagnetic shielding and thermal conductivity, our broad Specialties portfolio and expertise are available to help enable the global electric vehicle revolution.

The LNP™ portfolio features a range of product families that include LUBRICOMP™ lubricated compounds, LUBRILOY™ lubricated compounds based on alloy technology, THERMOCOMP™ reinforced compounds, THERMOTUF™ impact modified compounds, STAT-KON™ electrically conductive compounds, STAT-LOY™ anti-static compounds, VERTON™ long fiber-reinforced thermoplastics (LFRTs), FARADEX™ EMI/RFI shielding compounds, KONDUIT™ thermally conductive compounds, and COLORCOMP™ custom-colored compounds. At LNP™ we ‘compound the answer’ to your specific challenges.

The LNP™ portfolio is now also leveraging a broad palette of LEXAN™-based polycarbonate copolymers with exceptional properties for compounding. The following LEXAN™ copolymers offers unique value compared to general purpose polycarbonate and include resin portfolios with high heat resistance (XHT & CXT), low temperature ductility (EXL), superior flow and ductility (HFD), prolonged resistance to UV exposure for outdoor applications (SLX), transparent flame retardancy at thin gage (CFR), and excellent flame, smoke and toxicity properties for mass transportation (FST).

The chemistry inherent to the polyphenylene ether (PPE) molecules creates mechanically strong polymers that are lightweight, high heat stable and char forming. The incorporation of various polystyrenes to PPE helps to create blends that mold and flow well in standard injection molding processes. NORYL™ resin generally exhibits excellent electrical properties that remain stable over a wide range of temperature, humidity and frequency variations. Such stability, together with a fine-tuned balance of thermal and impact properties, makes NORYL™ resin a potentially excellent candidate for a number of demanding battery pack applications. 

For example, select NORYL™ resin grades such as NORYL™ N1150 resin, with its high ductility, UL94 V0 flame retardancy (to 1.5 mm) and resistance to Li-ion electrolyte* are already enabling lightweight module enclosures for our customers. For larger pack enclosures where modulus is more critical, glass fiber filled NORYL™ NHP5054 resin is positioned offering greater stiffness and a UL94 V0 flame rating at 0.8 mm. With its high-energy absorption capabilities, cost effective NORYL™ GTX™ resin battery protection solution can help protect the battery during impact. The single-piece, engineered plastic honeycomb structure is e-coat capable and offers a weight reduction of up to 60% compared to multi-piece metal reinforcements.

ULTEM™ resins uniquely balance both mechanical properties and processability, offering design engineers exceptional flexibility and freedom. ULTEM™ resins are also inherently flame retardant and possess excellent dielectric character. ULTEM™ resins are therefore an excellent candidate for your electric vehicle battery needs where high heat resistance is required. ULTEM™ resin is available in transparent and opaque custom colors, and can be glass filled for added stiffness. 

With its appreciable flow and dimensional stability, coupled with excellent resistance to Li-ion electrolyte, ULTEM™ resins such as ULTEM™ CRS5011 resin are today being used for insulation of Li-ion cell terminals. Given its excellent dielectric character, ULTEM™ resin is also an ideal candidate for bus bar insulation. For other powertrain elements, such as DC power converters, ULTEM™ UTF120 dielectric film is already enabling high temperature film capacitors. Contact us to learn more. 

As the mobility industry faces growing pressure to increase fuel efficiency and reduce tailpipe emissions, the case for vehicle electrification grows evermore strong. Concomitantly, 48 V mild hybrid electric vehicles (MHEV), enabled by 48 V batteries, are poised to grow considerably in the coming years.

Depending on crush requirements, 48 V Li-ion batteries may be constructed using all-plastic enclosures, helping battery designers to save weight. The Specialties portfolio contains a range of mechanically resilient, lightweight materials with added functionality such as UL94 flame retardancy and thermal conductivity that can aid passive cooling.

In supporting our customers’ flexibility in electric vehicle battery design, SABIC’s Specialties business offers a range of injection moldable materials for retaining cylindrical and pouch cell formats.

Working with you, our customers, we can tailor material characteristics to meet your needs such as level of flame retardancy, UV transmission or flow.

High voltage (>60 V) electric vehicle battery pack enclosures can contribute significant weight to the overall battery pack, impacting its specific energy (Wh/kg).

Certain high performance engineering thermoplastic materials can replace traditional metals, saving weight and easing the burden of cumbersome processing.

Depending on individual requirements, such as pack dimensions, Specialties’ portfolio of materials including flame-retardant

NORYL™ Resin, LNP™ VERTON™ and LNP™ THERMOCOMP™ compounds can offer the necessary qualities for electric vehicle battery upper enclosures.

Where ultimate strength is required, customers may elect to utilize UD-MAX™ tape in combination with appropriate base materials.

Specialties’ dedicated CAE teams can work directly with you can work directly with you to help tailor a range of next-generation, lightweight battery pack solutions.

Our customers tell us that safety is of the utmost importance. Common electric vehicle battery side impact countermeasures are forged from multi-piece steel stamping and extruded aluminum profiles. Such solutions are heavy at a time when weight-saving is increasingly desired.

SABIC’s Specialties business can offer singe-piece, lightweight side impact countermeasures fashioned from engineered honeycomb structures using NORYL GTX™ resin, saving our customers up to 60% in weight compared to multi-piece metal reinforcements.