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Two-wheeler technical know-how: DSM’s materials provide strength & durability that electric scooters need

25 March 2019
  • Dr Tamim Peter SidikiGlobal Marketing Director Electronics at DSM Engineering Plastics

Crowded Asian cities provide an incredible opportunity for the growth of the e-scooter market. The high cost of internal combustion and electric cars is one significant reason, but e-scooters provide more mobility on traffic-clogged streets where there is limited availability of parking spaces and charging stations for cars.

Government action to reduce air pollution will further drive the market towards e-scooters. At the end of 2018, the local government in Delhi, India, released a draft policy that has a target mandate for 25% of all new vehicle registrations in the city to be electric. Yet, the lack of charging infrastructure for electric cars further impedes growth for this market segment. E-scooter batteries, on the other hand, can be designed to be portable and charged wherever a standard electrical outlet is available.

A number of e-scooter components require specialized materials to ensure safe and reliable performance. DSM’s portfolio includes materials designed to meet the specific needs of these applications.

Connectors

Two-wheelers require high-voltage charging and interconnection systems to enable sufficient power to drive the main e-motor and produce acceptable battery charging times. Yet, with high voltages, engineers need to take extra care in the design of parameters, such as dielectric strength, creep and tracking resistance.

DSM offers a wide range of flame-retardant plastics that deliver the required electrical performance, with a Comparative Tracking Index (CTI) of more than 600V, dielectric strength of more than 30kV and a Relative Temperature Index (RTI) of 140°C. These compounds, available in a variety of colors, are halogen- and red phosphorous-free, so they can achieve the high CTI required for these applications and deliver the highest level of flame retardancy with a UL94-V0 rating.

By avoiding any ionic heat stabilizers, DSM has ensured full protection against potential electric corrosion of assembly bins or critical aluminum bonding wires within semi-conductor chips. Our materials offer the high mechanical strength of polyamides and work with a variety of assembly designs, including press fit, wave soldering and reflow soldering.

Connectors are an essential component in any e-scooter assembly. These connectors must maintain their integrity over the lifetime of the vehicle, even in the harshest environmental conditions, including exposure to dust, moisture, temperature cycling, chemical exposure and intense vibrations.

Connectors need to meet the following requirements:

  • Unlimited shelf life (JEDEC MSL1)
  • No pin corrosion (by using an insulation material free from halogens and red phosphorous and without ionic heat stabilizers)
  • High continuous use temperatures of 150-180°C
  • Excellent chemical resistance
  • High ductility
  • High electric strength and CTI of 600V or higher

Our best-in-class material solutions, ForTii JTX2 and ForTii Ace JTX8, combine the dimensional stability and low moisture-absorption of polyesters with the high mechanical strength of polyamides. ForTii Ace JTX8 is the only material in the world that meets JEDEC MSL1 while ensuring zero blistering over an infinite shelf life.

With the highest mechanical strength, it ensures excellent reliability during assembly and after years of use in harsh conditions. DSM also offers ForTii T11, which delivers the highest level of flame retardancy with a UL94-V0 @ 0.2mm rating.

Talk to us today about the material requirements for your e-scooter connectors. You can also visit plasticsfinder.com for additonal technical information. 

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