For every 10% weight reduction of new energy vehicles, the battery life can be increased by 6%-8%. This data drives the application rate of PC/ABS alloy in automotive parts to surge. Elix Ultra 4105 LNS308 alloy, developed by BMW Group and Elix Polymers, successfully replaced metal glove boxes. By optimizing flow properties, the injection molding cycle was shortened by 20%, and the scrap rate was reduced by 15%. It was applied to 1 Series, 3 Series and other models.
Technological breakthroughs focus on three scenarios:
- Spray-free process: Domestic spray-free PC/ABS achieves a metallic appearance and is applied to exterior trims such as door handles, reducing painting costs by 28% and VOC emissions per vehicle by 1.2kg;
- Laser welding PC: The laser transmittance of glass fiber reinforced PC alloy reaches 45%, and the welding strength is 25MPa, which increases the production efficiency of battery pack cover by 50%, and the air tightness reaches IP67 standard;
- Flame retardant upgrade: Halogen-free flame retardant PC/ABS is modified with layered silicate, and the peak heat release rate decreases by 62%, becoming the core material of CATL battery separator.
Domestic substitution is accelerating: Dongguan Xinsuyuan 10% glass fiber reinforced PC (heat deformation temperature 146℃) replaces SABIC PC 500R for new energy vehicle bumpers, with an impact strength increase of 30% and a cost reduction of 20%8. SABIC’s Xenoy HMD series PC/PET alloy has a thermal expansion coefficient as low as 4.5 and a fatigue resistance increase of 40%, which is used in power tool housings and fuel tank caps
