Thermal Management

With the higher performance of power electronics such as inverters, OBCs/DC-DC converters, and ECUs, thermal management is also becoming more sophisticated and complex. At the same time, the need for smaller and lighter EVs is increasing, and the replacement of components conventionally using metals with resin is progressing. Toray contributes to extending cruising range and expanding interior space by providing resin materials.

Grades

A673M T

PPS used for resin water jackets exhibits excellent insulation properties, dimensional stability, and hot water resistance compared to other resin materials in the high-temperature and high-humidity environments where coolant passes. A673MTB has excellent toughness among PPS resins and the high weldability required for resin water jackets, and enables undercut molding, which is difficult to process. It contributes to the formation of complex waterways and the downsizing and efficiency improvement of components.

An integrated cooling module is a system that integrates cooling components such as electric water pumps and valves into one. It contributes to lightweighting of cooling components and the entire vehicle, and improving space efficiency, realizing optimal thermal management. In particular, it contributes to improving the performance of various powertrain components that require efficient thermal management, such as engines and PCUs. Because it consists of multiple components, Toray proposes optimal resin materials for each component.

Grades

A504 CX1 (Impeller)

A675 GS1 (Valve/Housing)

For the impeller, the high-strength PPS resin material "A504CX1B", which has extremely excellent properties against high-temperature coolant, is optimal. For valves and housings, "A675GS1B", which realizes precise control of flow paths and high dimensional accuracy of components, is optimal. It is a grade that can also handle a wide range of processing methods, such as insert molding of metals like collars that make up the housing.

PA66/PP Alloy Materials (Housing/Manifold)

Components through which coolant flows, such as manifolds, require excellent chemical resistance. We have developed a material that alloys PA66 and PP using our proprietary technology. This material has lower water absorption than PA66, and has excellent various physical properties upon water absorption, such as improved coolant resistance. Also, because it has higher heat resistance than PP, it exhibits excellent performance even under more severe environments.

Electric water pumps efficiently cool the powertrain and improve energy efficiency by supplying the required amount of coolant independent of engine speed. Also, because they are small, lightweight, and highly durable, and contribute to vehicle lightweighting and fuel efficiency improvement, their use is advancing especially in hybrid electric vehicles and electric vehicles.

Grades

A673M T

This is a PPS material that exhibits excellent performance in high-temperature and high-humidity environments. It is a high-impact grade with excellent pressure resistance against high-pressure coolant circulating in waterways, and it also excels in heat cycle performance. It is also optimal for undercut molding to improve the airtightness of joints, contributing to improving component reliability.

Resin cooling pipes are lighter than metal pipes and have excellent insulation properties and chemical resistance, making them optimal as automotive components. Also, because molding is easy, they can accommodate complex shapes. Toray contributes to vehicle lightweighting and fuel efficiency improvement by providing such materials.

Grades

B670SF1B1

This is a new PPS resin with the world's highest level of flexibility, and is an optimal grade for automotive piping components. While maintaining high heat resistance and chemical resistance, it realizes flexibility suitable for processing methods such as bending processability and vibration durability, which were difficult with conventional PPS resins. In addition to proposing optimal piping such as multi-layer tubes, Toray can propose analyses such as blow molding and bending processes, which were difficult to reproduce with CAE, as our proprietary solutions.