HC Plastics News: It is estimated that by 2020, the production of pure electric vehicles, hybrid vehicles and plug-in hybrid vehicles will account for 5%-8% of total vehicle production. At present, automakers are mainly focused on technologies that extend cruising range and reduce costs to attract ordinary drivers.
In June, Swedish automaker Volvo announced that all new models will be electrified from 2019, once again demonstrating the company's firm support for electric vehicles. Coincidentally, Tesla also released the first affordable electric model 3, which costs less than $40,000 and has a cruising range of 200 miles.
“The demand for hybrid and electric vehicles is becoming more and more urgent.†Lou Jianfeng, senior vice president of global business unit of BASF Battery Materials, said: “All car manufacturers, regardless of size, are competing to reduce costs, increase cruising range and ensure safety. Sex, and extend the life."
From battery materials to lightweight components that reduce energy consumption, BASF offers its customers complete electric mobility solutions and helps car manufacturers address these challenges through research and development.
Battery material
Optimizing battery science is the fundamental way to increase the cruising range of electric vehicles/hybrids, extend service life and reduce costs.
To this end, BASF invests extensively in research and development to provide its customers with a comprehensive portfolio of materials; it also builds capacity in global strategic markets and assists customers in solving intellectual property issues through a reasonable mandate, including cooperation with the US Department of Energy's Argonne National Laboratory. Mass production and sales of nickel-cobalt-manganese (NCM) composite cathode materials, and patent agreement with CAMX Power LLC for high nickel positive electrode patent material CAM-7.
“Advanced materials science is the key to meeting industry needsâ€
Reducing the use of expensive, rare reserves of cobalt, replaced by cheaper, more abundant elements, is the industry's development trend; increasing nickel and manganese content is one of the ways. In the batteries used in early electric vehicles, the ratio of cobalt to other elements was relatively balanced; but now the proportion of nickel has reached 60%, sometimes as high as 80%.
At the same time, BASF also cooperates with universities, universities and partner companies to invest in and develop system solutions for all solid-state batteries and lithium negative electrodes.
“Advanced materials science is the key to meeting the needs of the industry,†said Michael Fetcenko, managing director of BASF's battery materials in North America. “These cathode materials have not been fully optimized, so BASF believes it is expected to address these challenges through incremental improvements and breakthroughs to make electricity Cars and hybrids meet the ever-increasing expectations of end users. With the rapid growth of the market, our global manufacturing and R&D network, as well as expertise in materials, will be the foundation of BASF's industry."
Characteristic material
As with the technical challenges of solving battery materials, reducing vehicle weight, reducing flammability, reducing arcing, and using highly engineered materials to avoid physical and chemical aging of components are also key to achieving electrification of traffic.
The larger the battery, the stronger the battery life, but they also increase the weight of the vehicle and provide higher requirements for thermal management. Faced with these challenges, BASF continues to expand its portfolio of plastic products to meet the requirements of next-generation battery technology with innovative solutions of unique properties.
For example, the weight of an outer casing made of thermoplastics can be reduced by up to 30% compared to metal parts. When using 35% glass-reinforced BASF Ultramid®, first-line suppliers can even lose 51%.
In addition, thanks to its excellent strength and high temperature resistance, Ultramid® thermoplastics can also be used to produce battery frames. These unique properties not only extend the life of the battery pack, but also improve its performance. With proper processing techniques, these materials provide outstanding strength and weight while ensuring dimensional stability of the end plates.
BASF continues to expand its portfolio of plastic products to meet the requirements of next-generation battery technology with innovative solutions of unique properties.
The thermally conductive conductive resin can also reduce the amount of metal and increase the level of lightness. BASF offers its customers new Ultramid® antistatic materials with good physical and mechanical properties, as well as other products with better strength, stiffness and conductivity.
The BASF material portfolio is also used in a variety of high voltage connectors, cables and charging infrastructure. These products include both halogen-free/red-phosphorus-free flame retardants and polybutylene terephthalate, the only hydrolysis-resistant flame retardant on the market. In addition, BASF Ultramid AdvancedN solutions not only have excellent physical properties in high temperature environments, but also withstand the test of corrosive media; due to the extremely low moisture absorption rate, the product can maintain dimensional stability in humid environments.
Bardot® elastic open cell foams made with thermoset polymers offer yet another ideal lightweight solution for electrification applications. Its excellent high temperature resistance and flame retardancy not only protects engine components, but also protects surrounding components that cannot withstand high temperatures for extended periods of time.
“Automotive manufacturers looking to build electrified products need to use engineering plastics solutions to provide high temperature protection and reduce overall weight for precision components,†said DaliaNaamani-Goldman, North America Electric Transport Industry Manager, BASF's Specialty Materials Division: “The lighter the weight, the battery The longer the endurance; the single-charge cruising range is one of the most important distinguishing factors at present, so this is very important for the market."
Reduce noise
In addition to reducing or even eliminating emissions, a quiet and smooth driving experience is undoubtedly one of the most attractive advantages of electric vehicles.
But many people don't realize that noise, vibration and roughness (NVH) pose many challenges for engineers. Although electric vehicles do not have the noise of traditional internal combustion engines, engineers must redefine and optimize the sound, comfort and experience of the car without affecting the driving efficiency of the vehicle.
BASF's NVH solution helps to meet this challenge. Using sound-insulating materials that greatly attenuate high-frequency noise, BASF helps manufacturers design innovative solutions that optimize acoustic comfort, vehicle dynamics and safety.
One example is the engine mount made with Cellasto® microcellular polyurethane elastomer, which effectively blocks and absorbs high frequency noise generated by electromagnetic pulses and torque pulses.
In addition, the Cellasto electric engine mount also helps to reduce weight and maintain sound quality and quality inside the car. Preliminary tests have shown that car manufacturers can reduce component weight by up to 30% when using Cellasto.
Reduce HVAC energy consumption
But these systems consume a staggering amount of energy, reducing battery life by up to 40%-50%.
In the hottest or coldest season of the year, many drivers turn on heating, ventilation and air conditioning systems for added comfort. In order to reduce the effects of sunlight and reduce the energy consumption in the interior of the car, BASF has developed a series of cool pigments to help control the temperature inside the car. Some of these dark pigments can even absorb up to 90% of the sun's heat. BASF's carbon black pigment reflects incident sunlight and reduces absorption, which lowers the surface temperature by 15-20 degrees Celsius.
While using cool pigments to help OEMs keep their car surfaces cool, BASF's Catalysts Division is also active to reduce the impact of heating and cooling systems on batteries. Utilizing advanced HVAC technology, BASF solutions increase recirculation efficiency, prevent moisture and carbon dioxide from entering the vehicle, and extend the cruising range of electric vehicles by up to 10%.
“BASF recognizes that automakers and suppliers are actively developing strategies to address the challenges associated with electrification and will continue to leverage their expertise in chemistry and materials to help customers move further.†Lou Jianfeng said . 
Editor in charge: Ye Dan
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