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Home > News > Automotive

(Focus) Plastics technologies driving next evolution of NEVs

Source：Adsale Plastics Network Date ：2025-02-24 Editor ：VC
Copyright： This article was originally written/edited by Adsale Plastics Network (AdsaleCPRJ.com), republishing and excerpting are not allowed without permission. For any copyright infringement, we will pursue legal liability in accordance with the law.

China's Ministry of Industry and Information Technology announced the mandatory national standard titled “Energy Consumption Limits for Electric Vehicles - Part 1: Passenger Cars” (Draft for Comments) on August 21, 2024. This standard establishes electric consumption limits for new energy vehicles (NEVs) as a mandatory requirement for the first time. The energy consumption of NEVs is closely linked to vehicle lightweighting, and a key advantage of high-performance plastics is their potential to replace heavier materials.

 

Meanwhile, autonomous driving technology is emerging as the “brain” of NEVs. The unique properties of high-performance plastics can meet the stringent requirements of related applications. Consequently, the use of automotive plastics in vehicle manufacturing is steadily increasing, and their applications are becoming more diverse in the automotive industry.

 

To refine the management mechanisms governing the energy consumption of NEVs

 

The calling for comments of the mandatory nation standard indicates the government's intention to enhance the energy consumption thresholds for vehicle models and to refine the management mechanisms governing the energy consumption of NEVs. These measures aim to promote the healthy development of the industry and encourage technological progress.


For models with fewer than three rows of seats and without four-wheel drive, energy consumption limits range from 10.1 kWh to 19.1 kWh per 100 km. Specifically, models with a curb weight between 1.09 tons and 2.71 tons must maintain their electric consumption below 13.92 kWh per 100 km. However, industry statistics indicate that as of August this year, only about 60% of these models meet the standard. This highlights the urgent need for effective means to reduce electric consumption.


EV_SAIC Motor_480.jpg

China plans to set electrical consumption limits for NEVs by establishing a national standard. (Source: SAIC Motor)


The national standard requirement clearly indicates that curb weight will be a key assessment criterion. The high curb weight of NEVs is closely linked to their powertrains. For instance, many battery packs from various brands weigh over 500 kg, with some even exceeding 700 kg.

 

Currently, this mandatory national standard is in the consultation stage. Based on industry practices, it may take about two years before the official release. Therefore, this is the ideal window for automakers to refine their lightweight technology strategies.

 

Automotive plastics facilitates safe and lightweight battery packs

 

The traditional fuel vehicle powertrain (engine and transmission) operates in a high-heat, high-wear environment, resulting in limited use of plastic parts. In contrast, the new energy power system, particularly the battery pack management system and other components, offers more favorable working conditions, making it easier to incorporate automotive plastics.


EV battery_Teijin_2_480.jpg

Automotive plastics have been increasingly used in battery pack design. (Source: Teijin)

 


(1) Need for flame retardant

 

Automotive plastics play a crucial role in the thermal management of battery packs. Thermoplastics with excellent flame retardant property can mitigate the risk of overheating in high-temperature and pressurized environments. Notably, polypropylene compounds (PPc) and long glass fiber (LGF) reinforced PP stand out.


SABICPR555a_480.jpg

Thermoplastics with excellent flame retardant property ensure stable operation of battery packs. (Source: SABIC) 


Leveraging the strengths of thermoplastics, SABIC has developed an innovative battery pack concept that integrates individual batteries into pouch cells. These cells are placed within a thin-walled housing molded with 30% glass fiber filled, flame-retardant PPc.

 

LG Chem and LX Hausys have also collaboratively created a special flame-retardant continuous fiber thermoplastic (CFT) designed to delay battery thermal runaway.

 

(2) Need for dust and water resistance

 

Power battery packs require stringent dustproof and waterproof ratings, with the industry standard being IP67. Some automakers, such as Geely, NETA, and ARCFOX, even claim capabilities of reaching IP68.

 

The key to enhancing the IP performance of battery packs lies in the sealing and securing of components around electrical connectors. These connectors, critical for maintaining the interface between the interior and exterior of the battery pack, must endure mechanical stress and environmental fluctuation.

 

Utilizing high-strength, wear-resistant materials like polyamide (PA) or polycarbonate (PC) can ensure the stability and sealing of connections, preventing moisture, dust, and other impurities from entering the inner part, thereby guaranteeing the reliable operation of the electrical system.

 

In addition, the significant gas generated by the battery pack after thermal runaway must be discharged promptly to prevent potential explosion. The support structure for safety devices, such as explosion-proof valves, is often made of specially designed plastic materials that can react quickly in emergencies. This ensures effective internal pressure release, further enhancing the safety of the battery pack.

 

Replacing steel with plastics in structural components of battery packs

 

The structural components of battery pack are vital parts of the electric vehicle energy system, significantly influencing the vehicle's overall performance, safety, and driving range.

 

Traditionally, high-strength steel has been the material of choice for the stamping forming structure of battery packs, owing to its excellent mechanical strength and impact resistance, which helps maintain structural integrity under complex working conditions.

 

In recent years, there has been a growing trend toward the use of automotive plastics in battery pack design, particularly in module housings and pack sealing covers. This shift aims to enhance lightweighting while still ensuring performance and safety.

 

Plastic materials such as PC, PA (particularly reinforced), and polyurethane (PU) not only possess densities much lower than steel, but also achieve comparable or even superior mechanical property and environmental aging resistance under specific formulations and processes.

 

For instance, the LGF reinforced flame-retardant PA material newly introduced by Shanghai PRET Composites Co., Ltd. is used to replace steel in structural components of battery packs. The material reduces component weight by 40% and lowers manufacturing costs by 15%.

 

Structural components of battery packs face challenges from mechanical vibration, high temperatures, high humidity, ultraviolet radiation, and chemical corrosion due to their harsh working environment. This imposes stringent performance requirements on materials.

 

To satisfy these requirements, the industry has made substantial advancements through ongoing exploration and innovation. A notable example is the successful application of PU solutions for battery pack top covers.

 

In a series of rigorous standardized tests, including assessments of mechanical properties, high-temperature and high-humidity aging, xenon lamp aging, acid and alkali resistance, high-temperature resistance, and insulation properties, PU materials have proven their viability and superiority as structural materials for battery packs.


HPRTM_Covestro_480.jpg

HP-RTM PU battery pack top cover solution. (Source: Covestro)


The Baydur® HP-RTM (High-Pressure Resin Transfer Molding) top cover for battery packs developed by Covestro is a key application of PU in NEVs. It is flame-retardant, lightweight and can be as thin as 0.8 mm.

 

Autonomous driving technology becomes new productive force

 

On the other hand, the “Opinions of the General Office of the CPC Central Committee and the General Office of the State Council on Accelerating the Construction of a Unified and Open Transportation Market”, released in December 2024, emphasizes the continuation of pilot applications, including autonomous driving, to promote the green and intelligent transformation of transportation.

 

Over 50 cities in China have implemented autonomous driving demonstration policies, with automakers highlighting autonomous driving features as key selling points for NEVs.

 

Autonomous driving technology is emerging as a new productive force supporting the development of NEVs. It not only fosters new business models, such as shared autonomous taxi services, but also drives innovation in related technologies.

 

The Advanced Driver Assistance System (ADAS) employs sensors to detect and collect data, integrating it with navigation information for comprehensive analysis. Among its functions, the Navigate on Autopilot (NOA) stands out.

 

NOA is a technology that combines assisted driving with navigation capabilities. When a vehicle is on a highway, NOA enables it to automatically change lanes, enter and exit ramps, adjust speed, as well as manage lights based on the onboard navigation route.

 

High potential of plastics in autonomous driving applications

 

ADAS has specific and unique material requirements, and plastics offer significant potential for related applications. For instance, millimeter-wave radar delivers reliable, high-resolution information for long-range targets, while the radar fairing protects the internal high-frequency antenna from weather and environmental damage. The materials used for the fairing must possess high strength and ensure that penetrating radio waves remain unaffected.

 

High-performance engineering plastics are not only easy to process but also exhibit excellent heat and chemical resistance. Additionally, certain plastics have a lower dielectric constant (Dk), enabling the radar's emitted radio waves to penetrate effectively, thus meeting the material requirements for millimeter-wave radar fairings.


ADAS_GAC_480.jpg

Advanced Driver Assistance System (ADAS) is central to autonomous driving technology, and plastics hold significant potential for related applications. (Source: GAC International)

 

As the ADAS market continues to expand, material suppliers are developing cutting-edge solutions. For instance, Envalior has recently launched a laser-weldable thermoplastic product portfolio for automotive radar, which includes polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), and PBT + PC grades.

 

Among these, the PPS grade has a low Dk, which ensures high radar resolution and minimal signal loss. It also boasts heat resistance up to 210°C, excellent hydrolysis and chemical resistance, contributing to extended component life and improved system reliability. The PBT + PC grade, specifically designed for radar casings, combines high strength, exceptional hardness, and excellent heat and chemical resistance. Additionally, it features a wide injection molding process window and outstanding deformation resistance.

 

SABIC has introduced two new modified materials with a high dissipation factor (Df), enabling efficient noise absorption. This improvement enhances the signal-to-noise ratio of millimeter-wave absorbing devices, leading to increased sensor accuracy and transmission range. The ultra-high flow and minimal warpage properties offer greater design flexibility.

 

A promising future

 

Advances in materials science and innovations in manufacturing process show a promising future for the application of automotive plastics in the power systems of NEVs. The choice of materials for battery pack structural components will become increasingly diversified. Striking a balance between lightweight design and high performance will emerge as a key focus for the industry moving forward. Furthermore, automotive plastics can enhance the efficiency and safety of autonomous driving, facilitating the development of intelligent vehicles and transforming the transportation landscape.


CHINAPLAS 2025 brings together highlights of automotive industry


The global automotive industry is undergoing constant transformation. Automotive plastics, as an important automotive component material, are developing towards high-performance, eco-friendly, intelligent, and electrification trends. 


CHINAPLAS 2025, the world's leading plastics and rubber trade fair, will stage at Shenzhen World Exhibition & Convention Center (Bao’an), PR China on April 15-18, 2025. 


The exhibition will join hands with over 4,000 international exhibitors, featuring the latest technology and process application solutions such as intelligent interior and exterior parts, low-carbon environmental protection, and safe endurance for the automotive industry, shaping the sustainable development of the automotive industry.


For more information or enquires about the show, please visit www.chinaplasonline.com.

 

Source: Song Yuan, Lecturer, Shanghai Donghai Vocational & Technical College; Adsale Plastics Network (www.AdsaleCPRJ.com)

 


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Battery management system
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 TAIZHOU HUANGYAN AOJIE PLASTIC MOULD CO., LTD.      

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Source：Adsale Plastics Network Date ：2025-02-24 Editor ：VC
Copyright： This article was originally written/edited by Adsale Plastics Network (AdsaleCPRJ.com), republishing and excerpting are not allowed without permission. For any copyright infringement, we will pursue legal liability in accordance with the law.

China's Ministry of Industry and Information Technology announced the mandatory national standard titled “Energy Consumption Limits for Electric Vehicles - Part 1: Passenger Cars” (Draft for Comments) on August 21, 2024. This standard establishes electric consumption limits for new energy vehicles (NEVs) as a mandatory requirement for the first time. The energy consumption of NEVs is closely linked to vehicle lightweighting, and a key advantage of high-performance plastics is their potential to replace heavier materials.

 

Meanwhile, autonomous driving technology is emerging as the “brain” of NEVs. The unique properties of high-performance plastics can meet the stringent requirements of related applications. Consequently, the use of automotive plastics in vehicle manufacturing is steadily increasing, and their applications are becoming more diverse in the automotive industry.

 

To refine the management mechanisms governing the energy consumption of NEVs

 

The calling for comments of the mandatory nation standard indicates the government's intention to enhance the energy consumption thresholds for vehicle models and to refine the management mechanisms governing the energy consumption of NEVs. These measures aim to promote the healthy development of the industry and encourage technological progress.


For models with fewer than three rows of seats and without four-wheel drive, energy consumption limits range from 10.1 kWh to 19.1 kWh per 100 km. Specifically, models with a curb weight between 1.09 tons and 2.71 tons must maintain their electric consumption below 13.92 kWh per 100 km. However, industry statistics indicate that as of August this year, only about 60% of these models meet the standard. This highlights the urgent need for effective means to reduce electric consumption.


EV_SAIC Motor_480.jpg

China plans to set electrical consumption limits for NEVs by establishing a national standard. (Source: SAIC Motor)


The national standard requirement clearly indicates that curb weight will be a key assessment criterion. The high curb weight of NEVs is closely linked to their powertrains. For instance, many battery packs from various brands weigh over 500 kg, with some even exceeding 700 kg.

 

Currently, this mandatory national standard is in the consultation stage. Based on industry practices, it may take about two years before the official release. Therefore, this is the ideal window for automakers to refine their lightweight technology strategies.

 

Automotive plastics facilitates safe and lightweight battery packs

 

The traditional fuel vehicle powertrain (engine and transmission) operates in a high-heat, high-wear environment, resulting in limited use of plastic parts. In contrast, the new energy power system, particularly the battery pack management system and other components, offers more favorable working conditions, making it easier to incorporate automotive plastics.


EV battery_Teijin_2_480.jpg

Automotive plastics have been increasingly used in battery pack design. (Source: Teijin)

 


(1) Need for flame retardant

 

Automotive plastics play a crucial role in the thermal management of battery packs. Thermoplastics with excellent flame retardant property can mitigate the risk of overheating in high-temperature and pressurized environments. Notably, polypropylene compounds (PPc) and long glass fiber (LGF) reinforced PP stand out.


SABICPR555a_480.jpg

Thermoplastics with excellent flame retardant property ensure stable operation of battery packs. (Source: SABIC) 


Leveraging the strengths of thermoplastics, SABIC has developed an innovative battery pack concept that integrates individual batteries into pouch cells. These cells are placed within a thin-walled housing molded with 30% glass fiber filled, flame-retardant PPc.

 

LG Chem and LX Hausys have also collaboratively created a special flame-retardant continuous fiber thermoplastic (CFT) designed to delay battery thermal runaway.

 

(2) Need for dust and water resistance

 

Power battery packs require stringent dustproof and waterproof ratings, with the industry standard being IP67. Some automakers, such as Geely, NETA, and ARCFOX, even claim capabilities of reaching IP68.

 

The key to enhancing the IP performance of battery packs lies in the sealing and securing of components around electrical connectors. These connectors, critical for maintaining the interface between the interior and exterior of the battery pack, must endure mechanical stress and environmental fluctuation.

 

Utilizing high-strength, wear-resistant materials like polyamide (PA) or polycarbonate (PC) can ensure the stability and sealing of connections, preventing moisture, dust, and other impurities from entering the inner part, thereby guaranteeing the reliable operation of the electrical system.

 

In addition, the significant gas generated by the battery pack after thermal runaway must be discharged promptly to prevent potential explosion. The support structure for safety devices, such as explosion-proof valves, is often made of specially designed plastic materials that can react quickly in emergencies. This ensures effective internal pressure release, further enhancing the safety of the battery pack.

 

Replacing steel with plastics in structural components of battery packs

 

The structural components of battery pack are vital parts of the electric vehicle energy system, significantly influencing the vehicle's overall performance, safety, and driving range.

 

Traditionally, high-strength steel has been the material of choice for the stamping forming structure of battery packs, owing to its excellent mechanical strength and impact resistance, which helps maintain structural integrity under complex working conditions.

 

In recent years, there has been a growing trend toward the use of automotive plastics in battery pack design, particularly in module housings and pack sealing covers. This shift aims to enhance lightweighting while still ensuring performance and safety.

 

Plastic materials such as PC, PA (particularly reinforced), and polyurethane (PU) not only possess densities much lower than steel, but also achieve comparable or even superior mechanical property and environmental aging resistance under specific formulations and processes.

 

For instance, the LGF reinforced flame-retardant PA material newly introduced by Shanghai PRET Composites Co., Ltd. is used to replace steel in structural components of battery packs. The material reduces component weight by 40% and lowers manufacturing costs by 15%.

 

Structural components of battery packs face challenges from mechanical vibration, high temperatures, high humidity, ultraviolet radiation, and chemical corrosion due to their harsh working environment. This imposes stringent performance requirements on materials.

 

To satisfy these requirements, the industry has made substantial advancements through ongoing exploration and innovation. A notable example is the successful application of PU solutions for battery pack top covers.

 

In a series of rigorous standardized tests, including assessments of mechanical properties, high-temperature and high-humidity aging, xenon lamp aging, acid and alkali resistance, high-temperature resistance, and insulation properties, PU materials have proven their viability and superiority as structural materials for battery packs.


HPRTM_Covestro_480.jpg

HP-RTM PU battery pack top cover solution. (Source: Covestro)


The Baydur® HP-RTM (High-Pressure Resin Transfer Molding) top cover for battery packs developed by Covestro is a key application of PU in NEVs. It is flame-retardant, lightweight and can be as thin as 0.8 mm.

 

Autonomous driving technology becomes new productive force

 

On the other hand, the “Opinions of the General Office of the CPC Central Committee and the General Office of the State Council on Accelerating the Construction of a Unified and Open Transportation Market”, released in December 2024, emphasizes the continuation of pilot applications, including autonomous driving, to promote the green and intelligent transformation of transportation.

 

Over 50 cities in China have implemented autonomous driving demonstration policies, with automakers highlighting autonomous driving features as key selling points for NEVs.

 

Autonomous driving technology is emerging as a new productive force supporting the development of NEVs. It not only fosters new business models, such as shared autonomous taxi services, but also drives innovation in related technologies.

 

The Advanced Driver Assistance System (ADAS) employs sensors to detect and collect data, integrating it with navigation information for comprehensive analysis. Among its functions, the Navigate on Autopilot (NOA) stands out.

 

NOA is a technology that combines assisted driving with navigation capabilities. When a vehicle is on a highway, NOA enables it to automatically change lanes, enter and exit ramps, adjust speed, as well as manage lights based on the onboard navigation route.

 

High potential of plastics in autonomous driving applications

 

ADAS has specific and unique material requirements, and plastics offer significant potential for related applications. For instance, millimeter-wave radar delivers reliable, high-resolution information for long-range targets, while the radar fairing protects the internal high-frequency antenna from weather and environmental damage. The materials used for the fairing must possess high strength and ensure that penetrating radio waves remain unaffected.

 

High-performance engineering plastics are not only easy to process but also exhibit excellent heat and chemical resistance. Additionally, certain plastics have a lower dielectric constant (Dk), enabling the radar's emitted radio waves to penetrate effectively, thus meeting the material requirements for millimeter-wave radar fairings.


ADAS_GAC_480.jpg

Advanced Driver Assistance System (ADAS) is central to autonomous driving technology, and plastics hold significant potential for related applications. (Source: GAC International)

 

As the ADAS market continues to expand, material suppliers are developing cutting-edge solutions. For instance, Envalior has recently launched a laser-weldable thermoplastic product portfolio for automotive radar, which includes polybutylene terephthalate (PBT), polyphenylene sulfide (PPS), and PBT + PC grades.

 

Among these, the PPS grade has a low Dk, which ensures high radar resolution and minimal signal loss. It also boasts heat resistance up to 210°C, excellent hydrolysis and chemical resistance, contributing to extended component life and improved system reliability. The PBT + PC grade, specifically designed for radar casings, combines high strength, exceptional hardness, and excellent heat and chemical resistance. Additionally, it features a wide injection molding process window and outstanding deformation resistance.

 

SABIC has introduced two new modified materials with a high dissipation factor (Df), enabling efficient noise absorption. This improvement enhances the signal-to-noise ratio of millimeter-wave absorbing devices, leading to increased sensor accuracy and transmission range. The ultra-high flow and minimal warpage properties offer greater design flexibility.

 

A promising future

 

Advances in materials science and innovations in manufacturing process show a promising future for the application of automotive plastics in the power systems of NEVs. The choice of materials for battery pack structural components will become increasingly diversified. Striking a balance between lightweight design and high performance will emerge as a key focus for the industry moving forward. Furthermore, automotive plastics can enhance the efficiency and safety of autonomous driving, facilitating the development of intelligent vehicles and transforming the transportation landscape.


CHINAPLAS 2025 brings together highlights of automotive industry


The global automotive industry is undergoing constant transformation. Automotive plastics, as an important automotive component material, are developing towards high-performance, eco-friendly, intelligent, and electrification trends. 


CHINAPLAS 2025, the world's leading plastics and rubber trade fair, will stage at Shenzhen World Exhibition & Convention Center (Bao’an), PR China on April 15-18, 2025. 


The exhibition will join hands with over 4,000 international exhibitors, featuring the latest technology and process application solutions such as intelligent interior and exterior parts, low-carbon environmental protection, and safe endurance for the automotive industry, shaping the sustainable development of the automotive industry.


For more information or enquires about the show, please visit www.chinaplasonline.com.

 

Source: Song Yuan, Lecturer, Shanghai Donghai Vocational & Technical College; Adsale Plastics Network (www.AdsaleCPRJ.com)

 


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