Electric vehicles (EVs) are reshaping the automotive industry, driven by stricter CO2 emission regulations and growing consumer demand for greener options. Ensuring EV battery safety and efficiency requires innovative thermal management systems (TMS). Envalior’s advanced material solutions offer exceptional performance, cost savings, and reliability, supporting the future of electric transportation.

The importance of thermal management systems for EVs

Automakers are rapidly investing in EVs to meet emission standards and consumer demand. The cost of an EV is predicted to be comparable to the cost of a gas-powered vehicle, thanks to advancements in battery technology. These innovations, which enable longer ranges and faster charging, are fueling an EV market projected to grow to $2.5 billion USD by 2027.

Unlike internal combustion engines (ICE), EV batteries operate within a narrow temperature range to ensure energy efficiency and prevent thermal runaway—where temperatures exceeding 65°C can create fire hazards. TMS are essential for maintaining this range, extending battery life, and ensuring safety. Additionally, TMS continue operating during fast-charging to manage heat generated by EV batteries, requiring thermoplastic components to withstand over 10,000 hours of coolant exposure.

Lightweighting and enhanced design for coolant control

In EVs and hybrids, TMS use electric water pumps and coolant control valves for precise temperature regulation. These components must meet complex design requirements while being lightweight. Manufacturers are increasingly replacing metals in TMS with engineering thermoplastics, which offer cost-efficient solutions and high performance.

Polyphenylene sulfide (PPS) is a popular choice for TMS components, known for its hydrolysis resistance and mechanical strength. However, polyamides (PA) are emerging as a versatile alternative, meeting specific application needs while delivering reliable performance. Envalior provides a robust portfolio of materials, including Xytron™ PPS, ForTii® PPA, Akulon® PA66 and EcoPaXX® PA410, tailored to diverse TMS applications such as coolant tubing, electric control valves, and water jackets.

Xytron™ PPS: Industry-leading thermal management material

Xytron™ G4080HR stands out in the TMS market due to its superior bonding interface between glass fibers and PPS resin, optimizing hydrolysis resistance and mechanical strength. Long-term testing in water glycol (50%/50%) at 135°C revealed the following advantages:

• Tensile strength: 114% higher than competing PPS after 3,000 hours of coolant aging.
• Elongation at break: 63% higher after prolonged exposure.
• Weld line strength: 85% higher after 1,000 hours of coolant aging.

These results demonstrate Xytron’s exceptional durability and its low leaching properties, which are crucial for TMS components, especially in hydrogen fuel cell vehicles.

Streamlining production for cost savings

The production of compact, intricate automotive components can be time-consuming and costly. Envalior’s materials help manufacturers streamline processes, minimize production errors, and shorten part approval cycles.

Our global team provides on-site support with advanced computer-aided engineering (CAE) molding tools, including Digimat-based anisotropic analysis, which predicts part performance with remarkable precision. The high flow properties of Xytron and other materials in our portfolio enable manufacturers to reduce cycle times, improve design flexibility, and lower operational costs.

With decades of expertise in automotive, electric, and electronic applications, Envalior collaborates with industry leaders to deliver sustainable, cost-effective solutions. Our strong partnerships with automotive OEMs ensure faster part approvals, helping manufacturers strengthen relationships and seize new growth opportunities in the rapidly evolving EV market.

Discover how Envalior’s advanced materials can optimize your EV thermal management systems. Contact us today or visit plasticsfinder.envalior.com to explore our innovative solutions for electric vehicle applications.