With automakers accelerating their shift to an all-electric future, SABIC continues developing thermoplastic-based solutions and harnessing its expertise to help the industry optimize the performance of electric vehicles (EVs). Most notably, the company’s automotive business has developed a plastic-intensive EV battery pack concept using a systems-engineering approach, which underscores the value of lightweight plastics to address critical industry needs for flexible design, enhanced performance, greater safety and improved economics.
Compared to conventional battery pack designs using traditional materials such as aluminum and other metals, SABIC’s concept using lightweight thermoplastics can potentially realize 30 to 50 percent weight savings per component, improve energy density, simplify the assembly process, reduce costs, improve thermal control and safety and enhance crashworthiness.
EV Battery Pack Concept
The SABIC-developed battery pack concept leverages the properties and strengths of thermoplastics to improve performance, reduce costs and weight, and support mass production. Highlights of the concept include:
- Integration of individual batteries into pouch cells placed within a thin-walled housing molded with a 30 percent glass fiber filled, flame retardant (FR) SABIC® polypropylene (PP) compound.
- Geometric features such as a double-wall construction, a novel rib pattern and creative functional integration – all enabled by SABIC thermoplastics to reduce weight and meet structural requirements.
- Creative use of the anisotropic thermal conductivity of plastics to optimize thermal management performance.
- Integrated plastic-metal hybrid structures with STAMAX™ FR long glass fiber PP material for the battery tray to optimize thermal transfer, meet drop test requirements and absorb the significant impact energy that side frame members can experience.
- A battery pack enclosure or cover molded with STAMAX FR resin. Use of this material meets the UL94 V-0 flammability rating and allows the cover to be metallized for electromagnetic interference (EMI) and radio frequency interference (RFI) shielding.
- Parts reduction and assembly efficiency, resulting in cost savings – enabled through the inherent design freedom of thermoplastics.
SABIC’s focus is to continue growing its expertise and offering to support innovation in EV batteries and additional EV applications. The company has assembled a technology team of chief engineers, research fellows and senior scientists. Their role is to provide world-class collaborative engagement with customers, development partners and others across the value chain, from OEMs and tiers to tooling suppliers and testing agencies.
“We are talking about a seismic shift in the automotive ecosystem,” said Al-Otaibi. “The industry can only build and improve upon today’s EV technologies if the entire supply chain is working together. This has long been SABIC’s way of thinking and style of operating. We will continue to pursue collaborative opportunities and partnerships that encourage innovation to thrive.”
Through ongoing work with the industry, SABIC expects several large battery enclosures, molded with its thermoplastics, to be used in production EVs as early as 2024. One plug-in hybrid electric vehicle (PHEV) model in China is already using SABIC PP compound instead of aluminum for its battery pack cover, providing weight savings, expanded design freedom, warpage control and other benefits.
Other EVs in production today around world are using several SABIC materials for components such as cell carriers and housings, battery modules and battery enclosures.
In addition to developing new materials to meet EV requirements, SABIC is working to enable technologies for large part manufacturing, joining and assembly, crashworthiness, battery thermal management, flame retardancy, electrical properties and performance testing.
SABIC is a global diversified chemicals company, headquartered in Riyadh, Saudi Arabia. It manufactures on a global scale in the Americas, Europe, Middle East and Asia Pacific, making distinctly different kinds of products: chemicals, commodity and high performance plastics, agri-nutrients and metals.
SABIC supports its customers by identifying and developing opportunities in key end-use applications such as construction, medical devices, packaging, agri-nutrients, electrical and electronics, transportation and clean energy. Production in 2020 was 60.8 million metric tons.
The company has more than 32,000 employees worldwide and operates in around 50 countries. Fostering innovation and a spirit of ingenuity, SABIC has 9,946 global patent filings, and has significant research resources with innovation hubs in five key geographies – USA, Europe, Middle East, South Asia and North Asia.
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© Press Release 2021