BASF, GM, and Lear Transform EVs with Innovative Injection Molding
- Alexander Fäh
- Nov 10, 2023
- 2 min read
BASF, General Motors, and Lear Corporation win the SPE Automotive Innovation Award for their groundbreaking Battery Disconnect Unit (BDU) in the 2022 GMC HUMMER EV.
The innovative injection molding process enables a 20% weight reduction and a 135% increase in current-carrying capacity, resulting in an additional 100 miles of range after just ten minutes of charging.
The BDU, supporting two 400-Volt systems for a safe, rapid charge, utilizes BASF's Ultramid® PA66 Polyamide and Ultradur® Polybutylene Terephthalate (PBT) for an overall weight reduction of 8% and a size reduction of 10%.
Collaborative Project Triumphs at SPE Automotive Innovation Award – Setting New Standards for Electric Vehicle Battery Systems through Injection Molding.
Renowned companies BASF, General Motors, and Lear Corporation have been honored with the Society of Plastics Engineers (SPE) Automotive Innovation Award in the category of electric and autonomous vehicle systems for their groundbreaking Battery Disconnect Unit (BDU) in the 2022 GMC HUMMER EV.
This innovative technology optimizes the battery pack design and results in a 20% weight reduction, while achieving an impressive 135% increase in current-carrying capacity. The outcome: an additional range of 100 miles after just ten minutes of charging.
The BDU, comprising several key components in every electric vehicle, transfers energy from the vehicle's battery pack or cells to the electrical system. Lear's design optimization and injection molding combine two units into one, supporting two 400-Volt systems for a safe, rapid charge.
Utilizing BASF's Ultramid® PA66 Polyamide and Ultradur® Polybutylene Terephthalate (PBT), Lear's BDU achieves an overall weight reduction of 8% and a size reduction of 10%.
“Through close collaboration with GM and our unique electrification solution of the BDU, Lear is excited to provide this streamlined component on the GMC HUMMER EV platform,” said Carl Esposito, Senior Vice President and President of E-Systems at Lear Corporation. “Based on the size of the BDU and its location within the vehicle, we knew plastic was the ideal material for the BDU’s extremely dense packaging.”
A key to the success of electromobility lies in how quickly the performance, range, safety, and reliability of electric vehicles continue to improve. BASF's innovations and expertise in electromobility contribute to making electric vehicles practically feasible for everyone.
“Co-collaboration with our customers and their customers enables them to deliver lightweight, cost-effective solutions in EV applications,” said Shane Tupper, Senior Technical Development Engineer, Performance Materials, BASF Corporation. “From expert design and engineering support to material selection, simulation, testing, and serial development, we provide the advantage of unique co-creation partnerships.”
