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Engineering Materials

Optimizing thermal management systems for EVs with advanced materials

Automakers are increasingly investing in electric vehicles (EVs) to meet stringent CO2 emission regulations set by governments, as well as consumer demand for greener vehicles. As automotive brands bring more EVs to market, they need to address the safety issues related to electric engine batteries.

In EVs, thermal management systems (TMS) are critical to keeping battery packs within the optimal temperature range to improve engine efficiency and service lifetimes as the EV operates. Additionally, TMS continue running when the EV is being charged to prevent battery pack thermal runaway – which is especially critical for fast EV charging. This requires manufacturers to ensure the thermoplastic components in TMS are tested to withstand more than 10,000 hours of exposure to coolant chemicals.

Understand why choosing DSM in thermal management systems

DSM supplies a complete portfolio of materials optimized for TMS components and works directly with our customers to identify the materials best suited to the specific needs of their applications. XytronTM, our leading PPS compound, is ideal for developing TMS components that require the highest hydrolysis and heat aging resistance, including thermal management modules, coolant control valves and electric water pumps. Our ForTii® PPA and EcoPaXX PA410 materials also offer proven performance in system components such as coolant tubing, electric control valves and water jackets.

DSM leverages our deep expertise in automotive, electric and electronic applications, and our best-in-class, cost-competitive materials to drive more value for our customers. Due to our strong partnerships with automotive industry leaders worldwide, manufacturers working with our materials often get parts approved by OEMs faster – leading to stronger business relationships. Our global services teams are prepared to support all your EV part manufacturing needs, and help you pursue a wide range of growth opportunities within the automotive market.

Explore DSM grades for thermal management systems

  • PPS - Xytron™

    Xytron is a high performance plastics compound based on linear polyphenylene sulfide. Xytron offers extreme chemical resistance, dimensional stability, and is intrinsically flame retardant.

  • PA4T PPA - ForTii®

    ForTii has a unique PPA's technology with high amide density. The ForTii platform includes polymers that are the highest crystalline, highest melting point and highest glass transition temperature amongst all PPA.

  • PA410 - EcoPaXX®

    EcoPaXX is a high-performance aliphatic, biobased polyamide that uniquely balances the benefits of typical short and long chain polyamides, such as low moisture uptake and high mechanical performance.

Browse thermal management applications

Coolant expansion tank

Automotive |

Application requirements Withstand under-the-hood temperatures of 105 to 150°C Internal coolant temperatures Withstand exposure to water/glycol Good welding properties Material properties Superior chemical stability and weld-line strength after ageing Excellent for under the bonnet conditions and temperatures

Coolant Hose T-Connectors

Automotive | Engine Cooling / Thermal management

70% is derived from renewable resources (tropical castor bean plant); Good thermomechanical properties; 30% weight reduction versus PA66; Heat-stabilized; Low moisture absorption

Thermal management modules

Automotive |

Broad portfolio of advanced material solutions for thermal management;Extensive global thermal management application development expertise;Xytron™ PPS offers best-in-class hydrolysis resistance and weld line strength

Water pump impellers

Automotive |

Broad portfolio of advanced material solutions for thermal management;Extensive global thermal management application development expertise;Xytron™ PPS offers best-in-class hydrolysis resistance and weld line strength

Engine water jackets

Automotive |

Broad portfolio of advanced material solutions for thermal management;Extensive global thermal management application development expertise;Xytron™ PPS offers best-in-class hydrolysis resistance and weld line strength

Contact us for more information

Direct and easy access to our broad portfolio of high-performance plastics: request a quote or order a sample. You can also simply ask our Thermal Management experts.

Gain more thermal management innovation insights

  • Optimizing thermal management systems for EVs with advanced materials

    As automotive brands bring more electric vehicles to market, they need to address the safety issues related to electric engine batteries. These batteries need to operate within a narrow temperature range to optimize energy efficiency and extend the engine’s service life – and risk thermal runaway that can create a fire hazard if they reach temperatures above 65°C.

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