In the U.S., the electric vehicle market continues to experience significant growth, accounting for 39 percent of global electric vehicle sales in 2014, according to the International Council on Clean Transportation. Product innovation is one of the key factors driving EV adoption, as advances in charging equipment and infrastructure are encouraging more U.S. drivers to choose sustainable options. Polycarbonates from Covestro – formerly Bayer MaterialScience – are playing a critical role in the development of effective, cost-efficient charging equipment for electric vehicles.
Covestro provided impact-resistant material capable of sustaining demanding mechanical force and environmental elements for the latest battery chargers offered by Lear Corporation, a leading global supplier of automotive seating systems and electrical power management systems.
The third-generation Lear portable charger is carried in the trunk of plug-in vehicles, including extended-range and fully electric vehicles, and offers drivers increased strength and safety. It passed all drive-over tests and was shown to protect all live parts even under severe weight loads. The product went into production in July 2015 and is expected to be commercially available next year.
The charger's body is injection molded from Makrolon® 2607 black polycarbonate and is approximately 3mm thick with honeycomb reinforcement for added durability. It is considered one of the most compact chargers on the market and is classified as a Level 1 (120V AC) or Level 2 (240 V AC).
"We worked closely with Lear to identify the right materials and process to improve the quality of the part and optimize production," said Ignacio Osio, Key Growth Programs Manager, Polycarbonates, Covestro. "Our team of engineers collaborated seamlessly to provide extensive mold design and welding assistance that helped to resolve early cosmetic and manufacturing challenges."
In addition to on-site processing support, Covestro provided thorough color-matching support to satisfy the optics requirements of the charger's LED lens, which is formed from clear Makrolon® polycarbonate.
"Electromobility requires material and process innovation," said Terry Davis, principal engineer at Covestro, who served as one of the product's lead designers. "Covestro is pleased to work with Lear to offer value-added electric vehicle solutions."
Attendees at The Battery Show, Sept. 15-17, can visit Covestro's booth (#2045) for more details about Covestro's material solutions for electric vehicles.
www.covestro.com