Bayer MaterialScience
Pioneering Material Solutions for the Electric Vehicle Charging Industry
Roland Berger estimates 8 – 10 million Electric Vehicles (EV) and Plug-in
Hybrid Electric Vehicles (PHEV) by 2020 worldwide.
Bayer – an inventor company and a global
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A growing and aging population, increasing urbanization,
escalating energy demand and climate change – we live in a
world full of challenges. Bayer MaterialScience is committed
to finding solutions to these challenges posed by global
megatrends. Bayer scientists are searching every day for
solutions that improve the quality of life. That’s our mission:
“Bayer: Science For A Better Life”.
Pioneering material solutions for
electric vehicle charging industry.
the
While one in ten automobiles is expected to be electric by
2020, a number of challenges must be overcome to achieve
this new reality. According to Nobuo Takanaka, Executive
Director at the International Energy Agency, the next decade
is a “make or break” period for EVs/PHEVs. Vehicles must
become lighter. Batteries must last longer and become
more affordable. Charging stations must be available. And
finally, consumer acceptance must be won.
How do we achieve this? What will such a world look like?
In order to fuel millions of EVs, an entire infrastructure of
charging stations must be built. This network will need
to integrate into the existing grid without overwhelming
its capacity. Charging stations will be needed in homes,
workplaces, shopping malls and at highway rest stops.
Charges will need to be quick while on the road, or may
be slow overnight. At great cost, charging stations must be
affordable to users and profitable to investors. Indoors or
outdoors, charging stations will be exposed to several forces
that influence their design and manufacture.
Safety is paramount to protect users and maintenance
personnel alike from high currents and short circuits. At
the same time, severe weather conditions and vandalism
must be withstood. Outdoor environments further require
chemical resistance and abrasion protection. And as
charging stations blend into our daily lives, attractive and
original designs will complement convenience and ease of
use. All these factors demand versatility and durability from
the components and materials chosen to make charging
stations strong, aesthetically appealing and scalable.
So while you worry about the technology, allow us to
relieve you of the worry about materials.
Pioneering Material
Solutions
For The Electric Vehicle Charging Industry
Polycarbonates and polycarbonate
blends from Bayer MaterialScience
are perfectly positioned to meet the
challenges faced by charging stations
and provide the following benefits.
• Impact resistant, even at very low temperatures,
therefore providing good protection against
vandalism.
• Flame retardant; UL 94 V-0 and 5VA ratings;
providing security against high currents in
case of damage
• Relative Temperature Indices, RTI
(mechanical, thermal, impact) up to 125 °C
• Light weight and lower in cost compared to
metal
• Wide selection of colors; available in
transparent and opaque options
• E
xcellent performance under any weather
conditions
• Chemical resistant
• Moldability and scalability
• Design freedom
“We needed a high impact- and temperatureresistant plastic, and knew Bayblend® would be
the best material we needed,” said Bram van de
Leur, the founder of EV Box. “The Bayblend® FR
3000 grade used offers high strength even in
extreme cold, is resistant to vandalism and other
mechanical stresses, is flame-retardant and the
material complies with the requirements of WEEE
and RoHS. Compared to other materials, the
polycarbonate blend also offers superior design
freedom, and would enable lower manufacturing
costs compared to traditionally used materials.”
“Bayer MaterialScience helped us select the
appropriate material. I can’t imagine anything
stronger for our product. It has exceeded
our expectations,” said Tony Vastola, senior
manufacturing engineer, Coulomb Technologies.
Coulomb uses Bayer MaterialScience’s Makrolon®
6557 for the display. The resin
offers the appearance of glass,
combined with the impact
strength and moldability of
Makrolon ® polycarbonate,
mak ing it ideal for
demanding lighting and
electrical applications.
The top piece that covers
the top of the charging
station is a black plastic
cap made of Makrolon®
6487 polycarbonate
resin. Coulomb engineers
vigorously tested
the durability of
this component,
and found it met
or exceeded every
specification.
The Bayer MaterialScience charging station prototype demonstrates applied material solutions.
The best way to understand the challenges and opportunities for material solutions
today and in the future was to build a prototype. Through this process, Bayer
MaterialScience technical engineers proved the impact of material choice on safety,
light weight, cost effectiveness and attractiveness of the charging station design.
Transparent cover: Makrolon® 6557
• Impact resistant, even at very low
temperatures, therefore providing
good protection against vandalism
• Flame-retardant; UL 94 V-0 compliance to RoHS, REACH
• Wide selection of colors; preferred for
transparent or translucent applications
• Suitable for outdoor applications;
f1 listing according to UL746C
• Chemical resistant
• Moldability and scalability
• Design freedom
Upper body: Makrolon® 6487/9417
• Impact resistant, even at very low
temperatures, therefore providing
good protection against vandalism
• 10 % glass fiber-reinforced Makrolon®
9417
•F
lame-retardant; UL 94 V-0 and 5VA
ratings; compliance to RoHS, REACH
• Wide selection of colors (opaque)
• Suitable for outdoor applications; f1
or f2 listing according to UL746C
• Chemical resistant
• Moldability and scalability
• Design freedom
Lower body: Bayblend® FR3010
• Impact resistant, even at very low
temperatures, therefore providing
good protection against vandalism
• Flame retardant; UL 94 V-0 and 5VA
ratings; compliance to RoHS, REACH
• Wide selection of colors (opaque)
• For improved weatherability requirements special grades are available
• Chemical resistant
• Moldability and scalability
• Design freedom
Registered design
Bayer MaterialScience LLC
100 Bayer Road
Pittsburgh, PA 15205-9741
www.materialscience.bayer.com
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