30 EV-charging infrastructure need multiple qualities to withstand the test of countless use cycles (plug-unplug), plus humidity, cold and sunlight due to being outdoors all year round, and even accidental car runovers on the plugs. In many cases, standard-grade polyamides and polycarbonates are starting to show their limits. There is demand for higher-performance thermoplastics to meet requirements while making the charging stations lighter, stronger and easier to repair. Plastic structures must be shielded, particularly with higher-power, fast chargers. With large currents flowing for charging up to 450 kW, the chargers must meet electromagnetic interference regulations (EMI), meaning the units must be shielded so they do not interfere with other nearby electrical equipment. All of this must be achieved while also ensuring the thermoplastics can be recycled to meet tightening regulations, particularly in Europe, which will eventually make it mandatory to include a proportion of recycled content in all types of infrastructure. The latest high-performance polyamide materials have recycled grades, while offering optimal resistance to humidity and long-lasting mechanical resistance, particularly for fast-charging plug connectors. This could increase the number of charging cycles they are capable of withstanding, so wear resistance is definitely a valuable property of the material. The thermoplastic materials for charging units are being tested with equipment makers, starting with plug connectors, but this is in the early stages. This protective function is also important for home charging units. This is another case for polycarbonates with robustness, corrosion resistance, electrical insulation and fire resistance. Importantly, the plastic can be produced in a highly environmentally-compatible manner for lower carbon emissions. It has been used for the first wall box made of the material that is climateneutral from cradle to factory gate. Materials research A European project is developing a hightemperature thermoplastic for electric aircraft. The aerospace sector typically uses lightweight, high-performance, thermosetting plastic composites, also known as epoxy resin-based composites, in many applications, but these materials are not as heat-resistant as other metal aircraft components. Components made from a thermoplastic base have been shown to be more efficient, from the perspective of their thermal properties, than thermosetting composites. A known property that makes them very useful is that they can be recast, reshaped, processed and recycled without the need for any additional curing process in order to harden and set. They are more versatile, cheaper and eco-friendly than conventional thermosetting composites, and they have a longer service life, thanks Focus | Polymer considerations for EV March/April 2024 | E-Mobility Engineering A fast charger handle using thermoplastic (Image courtesy of SABIC) Modelling thermoplastics for high-temperature use in electric aircraft (Image courtesy of Carlos III University)
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