Thermoplastic solutions for the e-mobility
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- Leo Howard
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1 Thermoplastic solutios for the e-mobility EIT Raw Materials Performace Materials Europe, BASF SE
2 BASF is a Key Supplier for the Automotive Idustry Coatigs Dispersios & Pigmets Performace Materials Catalysts Performace Chemicals EIT Raw Materials
3 CASE Today s Automobile Megatreds C The comprehesive commuicatio betwee cars, user, ad ifrastructure Coected Shared / services S A extesive offer aroud the ecosystem car ad the visio to share everythig A The visio of self-drivig cars without the eed for huma actio Autoomous Electric drive E The chage of the powertrai from iteral combustio to electric drives EIT Raw Materials
4 Aspects of the CASE Megatreds Affectig the Polymer World Itercoectivity Parts Novel Closure Cocepts More Actuators Cetral Cotrol Uits Adaptable Iterior Cocepts New Body Cocepts New Automobile Compoets Extesive Sesor Systems Electric Drivetrai Image source: Reault EIT Raw Materials
5 Challeges related to Automated Drivig Sesors RADAR Trasparecy Coectivity Heat maagemet Wirig Seamless itegratio Wirig Cleaability Redudacy Selectiveess Laser Ivisibility Shy Techology to see ad be see No iterferece Maiteace Fuctioality Desig Sesor fusio Safety Always o Black Box Image sources: Valeo, Audi, Mageti Marelli, GM, TactoTek, Velodye EIT Raw Materials
6 Polymer Materials for Radar Sesor Systems Challege Plastic materials ca impact radar sigal ad sesor performace Solutio BASF offers egieerig plastics portfolio of radar optimized products for better Radar trasparecy Radar reflectio Radar absorptio (products expected soo) Beefits Higher sesor efficiecy Reduced sigal clutter More effective sigal capturig ad processig More compact dimesios ad less weight Ecoomic maufacturig, assembly ad recyclig Applicatios Radomes, sesor housigs ad compoets, sesor mouts Image sources: Bosch, Cotietal, Remcom EIT Raw Materials
7 Pigmets with High Laser Beam Reflectio Challege Laser scaig sesors (LiDARs) caot cope with all surfaces ad colors Solutio NIR-reflectig pigmets of BASF Colors & Effects BASF supports the formulatio of safer paits for automated drivig eablig dark coatigs to be better visible for LiDAR sesors EIT Raw Materials
8 The Future will be Orage EIT Raw Materials
9 Schematic Desig of Power Supply i Electric Vehicles AC: Alteratig curret battery power supply BMS DC: Direct curret Electric motor ASM PSM AC-DC iverter HV auxiliary cosumer DC-DC coverter HV battery Charger ASM: Asychroous machie PSM: Permaet-cotrolled sychroous machie BMS: Battery maagemet system HV: High voltage EIT Raw Materials
10 Requiremets of HV Battery Systems battery Source: Audi Electric motor ASM High voltage battery PSM AC-DC iverter Requiremets: High mechaics Stiffess Stregth Impact Flame retardace EMI (elctromagetic iterferece) shieldig Chemical resistace power supply HV auxiliary cosumer DC-DC coverter BMS HV battery Charger AC: Alteratig curret DC: Direct curret ASM: Asychroous machie PSM: Permaet-cotrolled sychroous machie BMS: Battery maagemet system HV: High voltage EIT Raw Materials
11 Requiremets of HV Power Electroics battery Electric motor Source: Cotietal ASM PSM Source: Delphi AC-DC iverter power supply HV auxiliary cosumer DC-DC coverter High voltage power electroics: AC: Alteratig curret Requiremets: BMS Thermal coductivity DC: Direct curret Flame retardace ASM: Asychroous EMI (elctromagetic iterferece) shieldig machie HV battery PSM: Permaet-cotrolled sychroous machie Charger BMS: Battery maagemet system HV: High voltage EIT Raw Materials Source: Bosch Source: Bosch
12 The Electric Powertrai Temperature Electric Egie Power Electroics Coectors HV auxiliary cosumers Battery max C max.120 C max. 140 C max. 90 C max. 60 C Demagetizatio Meltig of widig isulatio Electroics safety Usually up to 100 C Maufacturers provide complete temperature rage to offer versatility Stadard automotive temperature rage Battery damage No chargig of Li cells below 0 C Image sources: Cotietal, GM The electric powertrai has differet requiremets tha a combustio powertrai but offers ew opportuities for egieerig plastics EIT Raw Materials
13 High Voltage Coectors & Chargig Couplers Glowig wire test: 850 C for isulators of curret carryig parts Product Material GWFI / flammability CTI Ultramid A3X2G5 PA66-GF25-FR 960 C / V Ultramid A3UG5 PA66-GF25-FR 960 C / V Ultramid A3U42G6* PA66-GF30-FR 960 C / V Ultramid A3U32 PA66-FR 960 C / V Ultradur B 4450 G5* PBT-GF25-FR 960 C / V Source: BASF Glowig wire test: 650 C for other isulators Product Material GWFI / flammability CTI Ultramid A3EG6* PA66-GF C / HB 550 Ultramid A3EG7 PA66-GF C / HB 550 Ultramid B3EG6 PA6-GF C / HB 575 Ultradur B 4300 G6 PBT-GF C / HB 375 Ultradur B 4331 G6* PBT-I-GF C / HB 500 *Available i orage (RAL 2003) Source: Meekes EIT Les Raw Matériaux Materials Polymères pour la Mobilité du Futur
14 EMI Shieldig Challege HV compoets emit/absorb electromagetic radiatio Electromagetic iterferece (EMI) disturbs drivetrai Eviromet ad compoets eed protectio Solutio Nowadays, most HV housigs are made of metals with EMI shieldig free of charge Less freedom of desig Heavy Fuctio itegratio challegig BASF works o polymer solutios for lightweightig HV housigs ad achievig the required EMI protectio Required rage of shieldig efficiecy Source Reflectio Absorptio Trasmissio Shield E 0 : Field stregth without shield E 1 : Field stregth with shield SE: Shieldig Efficiecy SE [db] = 20 ˣ log(e 0 / E 1 ) Sik SE [db] E 0 /E 1 Trasmitted power 20 10:1 10 % :1 1 % 60 1,000:1 0.1 % 80 10,000: % EIT Raw Materials
15 BASF Approaches to EMI Shieldig Coductive Plastics (3 mm thickess) Coductive Coatigs Ultramid A3WC4 (PA66-CF20) Ultramid A3WCG24 (PA66- CF10-GF20) Galvaic metal coatigs: ~ 60 db (< 20 µm) PVD/CVD metal coatig: db (2 10 µm) Metal combustio sprayig: db (100 µm) Ultramid B3WC3 (PA6-CF15) 30 Ultradur B 4300 C3 (PBT- CF15) 40 PA wt. % steel fibers 60 PA wt. % steel fibers EMI Shieldig [db] EIT Raw Materials
16 Summary BASF is already providig materials for electric vehicles New requiremets of e-mobility are idetified: Flame retardace EMI shieldig New solutios uder developmet First ideas realized ad ready for trials 16 EIT Raw Materials
17 BASF Performace Materials Your global parter for the future mobility Cotact details: Timo Prezer BASF Performace Materials Europe S timo.prezer@basf.com T M EIT Raw Materials
18 EIT Raw Materials
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