Key Applications of Composites in Electric Vehicles

One of the first methods that are considered to raise a vehicle's efficiency is to lighten the system as a whole. The development of lightweighting in vehicles dates to the early 1900s, when aluminium first gained traction in the automotive sector.

Fremont, CA: The transition from gasoline-powered to electric vehicles (EVs) is one of the most significant climate action goals adopted by world leaders to reduce climate change's negative effects. Given that transportation accounts for approximately a third of global emissions, the approach might offer some relief. EV sales have increased in recent years, and consumers all over the world have responded favorably to them. Multiple nations have set ambitious goals to increase EVs in their fleets. This would bring EV sales to 32 percent of all automobiles sold globally by 2030.

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Despite offering potential benefits in terms of emissions reduction, there are a number of obstacles that have prevented customers from adopting EVs widely.

The first and most common issue customers have with the current generation of EVs on the market is range restrictions and worries about car values. According to a survey by Alix Partners (2019), 67 percent of buyers want an EV that costs as much as a gas-powered car.

The inadequate charging infrastructure is a second significant issue, as the majority of stations are located in a few areas. A scarcity of charging stations has dissuaded 57 percent of buyers from buying EVs, according to a Alix survey. With the exception of China, Japan, and South Korea, it appears that the east has lagged far behind in closing this gap. This is despite western nations' efforts.

It will take time to overcome these obstacles. However, composite materials are contributing to a number of advancements to increase vehicle efficiency through lightweighting. Here, we'll look at advances in a number of parts, including motors, inverters, converters, battery modules, and vehicle drivetrains.

The relationship between efficiency and weight

One of the first methods that are considered to raise a vehicle's efficiency is to lighten the system as a whole. The development of lightweighting in vehicles dates to the early 1900s, when aluminium first gained traction in the automotive sector. Aluminium gradually replaced steel in vehicle parts, including the vehicle body.

In battery modules or enclosures, where composites have gained popularity, the most intriguing innovations can be noticed. With a metallic module of 100 kilograms, conventional EV batteries weigh more than 400 kilograms. Industry heavyweights like BMW (Munich, Germany), which has teamed with SGL Carbon (Meitingen, Germany) to offer carbon fiber composites for its battery modules, employ composites to reduce weight in the battery module.

The motor is a major contributor to the vehicle's weight. Therefore, weight can be reduced with design, integrations of electrical components, and the choice of suitable materials. Currently, organizations like Hyliion (Cedar Park, Texas, U.S.) and Hofer (Nürtingen, Germany) are concentrating on the design and development of e-axles, which have a motor along with a converter or inverter while utilizing the fewest high-voltage connections possible.

Integration of interior and external structural components—a process that involves fewer parts and different designs—could be essential for weight reduction. Composites will play a significant role, however due to obstacles like rising material costs and part manufacturing complexity, widespread adoption may be hindered or delayed.

Way forward

From a consumer standpoint, EV demand is unlikely to surpass conventional gas-powered automobiles for the foreseeable future. In fact, government programs, investments, and incentives influence how quickly EVs are adopted. Additionally, because of their high unit costs and scale economies problems, we anticipate that structural components for luxury class cars will primarily be made of composite materials. Nevertheless, composites can be used in significant parts, such as battery enclosures and some motor sub-components (across all car classes), where we can anticipate further penetration in the next three to five years.