LANXESS new design concept for electric vehicle charging inlets

June 24, 2021 4:32 pm

Modular design based on its thermoplastic compounds – customised material solutions.

The boom in electric vehicles is causing a sharp rise in demand for plastics destined for charging infrastructure. LANXESS is convinced that this area offers a wealth of opportunities to use its Durethan polyamides and Pocan polyesters. The possibilities gained by these thermoplastic compounds are demonstrated in a new design concept from LANXESS for charging inlets. These are installed in battery electric vehicles and accommodate the charging coupler of the external charging station. 

Gregor Jaschkewitz, application developer at the High Performance Materials (HPM) business unit, who devised the design, explains, “Our approach is aimed at using a modular configuration to get the right material in the right place to meet the complex requirements applicable to the various components with the utmost precision. At the same time, a high level of functional integration is intended to make it as easy as possible to assemble the entire unit, which means screwless assembly and minimal components in order to keep costs low.” 

Transfer of expertise from projects

The design is the product of collaborative discussions with manufacturers of charging systems, and incorporates the experience that LANXESS has already accumulated in numerous charging infrastructure development projects. 

Jaschkewitz says, “This means that it also satisfies a desire expressed by many manufacturers to have the ability to be as flexible as possible when it comes to charging inlet sealing.” O-rings, sealing cords or family seals can be used, for example, as can be employed lip seals manufactured in a two-component injection moulding process. 

Integrated thermal management

The key elements of this charging inlet design are the front and rear housings, a socket for the connector from the charging station and an actuator. The latter locks the connector in place to prevent it from being accidentally or deliberately pulled out during the charging process. The pin holder is another essential element. It holds the metallic connector pins in place, as well as a printed circuit board (PCB) with cables for charging with direct or alternating current, among others. 

Particular attention was paid to the design of the pin holder. It positions the cables, such that the heat produced during charging is dissipated not only through them but also via the other cables not in use. 

For more info, visit: https://lanxess.com/