SPE Automotive Award

An assembly for the battery management of the high-voltage battery was developed for the Mercedes-Benz EQE. The module is installed in the battery box and regulates the current flows in the vehicle over the integrated temperature sensors, switching relays and current conductors. 
The two orange-coloured covers are made of Grilon BG-30 FR. The material is used due to its rigidity, high flowability, flammability in accordance with UL 94 V0 and high dielectric strength. The overmoulded busbars are made from an impact-resistant Grilon TSGZ-15. The high elongation at break of the EMS polyamide prevents the formation of cracks due to the different thermal expansions of copper and plastic at -40°C to +120°C. 

The covers of the busbars are made of Grilon TS V0. The unreinforced polyamide allows the components to be clipped together fully automatically. The extruded busbars are coated with a layer of Grilamid XE 3817, which was specially developed for adhesion to metals. Thanks to the very good elasticity and adhesion of the EMS polyamide, there is no detachment during the 3D forming process. The material also has excellent ageing resistance for over 3000 hours at up to 125°C. All components are mounted on a 1.2 metre long structural beam, which is made from a very easy-flowing Grilon BG-30 S. 

A highly innovative high-voltage connector has been developed for contacting high-voltage cables in electric cars up to 1000 V. These high-voltage connectors are currently the smallest and most compact connectors on the market for connections up to 95 mm2 cable cross-section. They are used for installation close to the engine in battery electric vehicles (BEV) and plug-in hybrid vehicles (PHEV) at temperatures from -40°C to 140°C.

The EMS polyamide Grilon XE 16076 with 60% glass fibre reinforcement, which was specially developed for this application, has 40% better flowability than conventional PA6 grades. The colour is colour-stable even after 1000 hours of storage at 150°C and allows easy laser marking. The excellent strength of the material prevents deformation while remaining flexible enough to operate clips and latches without tools. The material is halide-free, contains no metallic components and therefore ensures permanent insulation without the occurrence of contact corrosion.