Thermosets Used in EVs (Electric Vehicles)

As a performance grade composite, thermoset plastic materials are used in a variety of challenging automotive applications and environments due to the excellent heat resistance and temperature deflection properties. Common historical applications include powerpoint and transmission components, interior ash cups, solenoids, and other components needing to remain durable within tough applications. These properties allow molded thermoset parts to avoid deforming or degradation when exposed to high operating temperatures. Recently with the increase of EV (Electric Vehicle) production, thermosets are used more within automotive electrical applications to protect internal electronics such as PCBs, sensors, and charging components and allow safe connections between the electronic assembly and vehicle interface. Whereas thermosets have long been a heavy used material within electrical housings, connectors, switches, relays, and circuit breakers, the increase in EVs have provided a new market for thermosets, but with similar environments to its industrial electrical counterparts.
From a commercial standpoint, thermosets can be injection molded in high volume applications with the use of high cavitation molds. Raw material costs for thermosets such as Phenolics and BMCs are competitively priced in the $1.25 – $3.50 price per lb., allowing the materials to be used commercially in price sensitive applications as well. Common thermoset materials used in EVs include Phenolics, or phenolic molding compounds, and BMCs (Bulk Molding Compounds).