Headquartered in Belgium, Solvay has been a global leader in Materials, Chemicals and Solutions for decades, offering polymer-based solutions to bring innovation in planes, cars, batteries, medical devices, water and air treatment.
Delivering an extensive portfolio of speciality polymer solutions driving advancements in automotive sector, Aishwarya had a candid chat with Nicolas Batailley, eMobility Marketing Manager, Solvay on the ongoing designing issues electric vehicle battery makers are facing nowadays.
- Dealing in specialized polymer-based solutions, tell us about your latest offerings based on electric vehicle segment.
Solvay Materials has the broadest portfolio of specialty polymers among the chemical industries which allows us to bring innovation almost everywhere in an Electric Vehicle. For example, we have developed a specific PEEK for magnet wire to replace enamel. Here we offer a higher thermal conductivity, a higher heat resistance, better mechanical properties, much better chemical resistance, etc. Recently we also have introduced on the market new LCP grades and PEEK films for slot liners. Like for the magnet wire the idea is to enhance the efficiency of the electric motor allowing to increase range and power of the electric vehicle.
We are also very active on Power Electronics with the development of a new technology to address EMI shielding. This new grade allows a metal substitution of the inverter casing to a much lighter solution (around 40%) with outstanding EMI shielding properties. We are also developing solutions for Busbars and power modules to help our customer to develop lighter, safer and more efficient Power Electronics.
And finally comes our new solutions for batteries…
- Advancing in the direction of developing 400 Volts systems, what are the possible challenges battery packs are facing in regards to performance, range and efficiency of electric vehicles?
Battery is obviously a key element in an Electric Vehicles. Carmakers collaborate with tiers and chemical companies to offer the best technologies to increase vehicle range at an affordable cost. Energy density of a pack is key to achieve this goal. This requires design optimization and relevant material selection for the pack. But this has to be done without any compromise on safety.
- Thermal runaway in battery module poses a great risk to the safety. What makes Solvay’s new product better than the existing options?
Thermal runaway is indeed one of the biggest challenges that the automotive industry is facing. To support the car makers to address this issue, Solvay has recently introduced 2 new specific grades. The first one is dedicated to battery module end plates insulation. The target was to develop a material combining the highest possible thermal resistance with the lowest possible thickness and the easiest processability. Our new Xydar LCP achieved these three requirements since it is able to resist to an exposure of 400°C during 30 min while retaining its dielectric properties. And this is possible with a 0,5 mm plate simply injected.
The second material has been specifically developed for Battery busbars. The objective here was to develop a material which protects the busbars against short circuit when exposed to a thermal runaway This material, also develop for injection molding, is able to resist a torch exposure at 1000°C during 25 minutes without breaching.
- Transitioning towards a clean mobility space, kindly mention the significance of research and development in polymers leveraged for electric mobility domain.
The polymer industry is facing an existing challenge. The molecules developed in the past for Internal Combustion Engines applications are not the one needed to support the electrification trend. Now our customers are requesting Thermal runaway resistance, dielectric performances, high CTI and RTI, Electromagnetic performances… This is why Solvay introduced these new materials and is working on the next generation of polymers. Our entire Research & Innovation and Marketing teams are focus on eMobility. I cannot say more today but the best is to come…
- Facing an extreme focus on sustainability and carbon neutrality in every industry, mention your take on this matter and key initiatives you have taken to mitigate this?
Indeed, sustainability is key for our industry and our customers.
Solvay Materials has been working on this topic since more than a decade…. To give you a concrete example, most of our resin is produced with renewable energy. This is an action we launched around ten years ago. And now Solvay is the only industrial company which has joined the Top Ten of biggest solar Energy users in the USA.
To give you another example we have launched a PPA partially bio-based developed for the eMobility market. This grade offers the lowest GWP among the PPA available today on the market. Finally, we are launching several mass balanced grades to help our customers to achieve their sustainability targets.
- Any comments on the nascent hydrogen fuel cell mobility. How do you look into its future?
Solvay has been active in the hydrogen field for many years. We are one of the leaders for Fuel Cell membrane materials. Based on this expertise we are helping our customers in the development of fuel cell mobility, not only for membranes but also for stacks, end plates, cooling loop, oxygen circuit, hydrogen circuit, etc. Here it is really important to understand both worlds (Fuel Cell and Polymers) to develop the best grades for this technology where purity is for example a key requirement.
- Kindly tell our readers about the Solvay’s latest research unit in France which is said to focus on developing materials for the next generation of solid-state batteries for electric vehicles?
Solvay is the front-runner in Europe on the design and scale-up of advanced inorganic solid electrolytes. These materials, developed & optimized in our R&D labs in Paris, are key components of so-called “all solid state batteries” that are expected to be a game changer in increased safety, improved performance (autonomy) and reduction of total battery costs, in order to meet rising demand for EV electrification. To demonstrate the industrial feasibility and scale up to semi-industrial size level, Solvay has opened a new pilot research unit at its plant in La Rochelle, France. This one-of-a-kind pilot asset will expand Solvay’s research and innovation capabilities in Europe.