As the electric vehicle (EV) industry continues to grow, automakers face mounting pressure to improve battery performance, system reliability, and passenger comfort. Central to all of these priorities is thermal management—specifically, how efficiently an EV cools its batteries, inverters, and power electronics.
Cooling systems that were once “good enough” are no longer viable in today’s high-voltage, high-efficiency applications. Traditional materials like metals and standard thermoplastics often degrade under the demands of modern EV platforms. To meet the challenge, manufacturers are increasingly turning to advanced engineering plastics such as Leona™, Xyron™, and Thermylene® from Asahi Kasei Plastics.
When EVs are on the road, components like lithium-ion batteries, electric motors, and onboard chargers generate substantial heat. Poor heat dissipation doesn’t just affect performance—it creates serious risks:
To address these risks, automakers need coolant system components that are lightweight, chemically stable, thermally resilient, and hydrolysis-resistant—especially in harsh underhood environments.
Historically, EV cooling components have used metals like aluminum or thermoplastics like PBT and PA6. While familiar, these materials come with drawbacks.
Metal Components
Standard Thermoplastics (PA6, PBT, PET)
This is where advanced plastics offer a better path forward.
1. Leona™ – High-Temperature Strength Meets Dimensional Stability
Leona™ is a high-performance PA66 developed for applications under constant pressure, heat, and fluid exposure. It delivers exceptional strength and heat resistance without the moisture absorption issues common in standard nylons.
Why it works:
Ideal for:
2. Xyron™ – Electrically Insulative and Chemically Durable
Xyron™ is a modified PPE resin known for its thermal stability and electrical properties. Unlike other resins, it maintains low dielectric loss while resisting aggressive automotive fluids.
Why it works:
Ideal for:
3. Thermylene® – Lightweight and Cost-Efficient for EVs
Thermylene® is an advanced polypropylene (PP) compound that offers a strong combination of light weight, durability, and cost efficiency. It’s particularly useful in multi-layer tubing and underhood parts where metal is overengineered.
Why it works:
Ideal for:
With decades of experience in both performance plastics and automotive innovation, Asahi Kasei delivers materials that consistently outperform legacy options. Benefits include:
EVs represent a seismic shift in vehicle design—and with that shift comes new thermal challenges. Choosing the right materials for cooling components isn’t just about solving today’s problems. It’s about preparing for tomorrow’s electrified future.
With Leona™, Xyron™, and Thermylene®, Asahi Kasei Plastics helps OEMs and Tier 1 suppliers develop cooling systems that are safer, lighter, more efficient, and built to last.
Want to test Asahi Kasei materials in your EV application? Contact our technical experts today to request a sample or discuss how our formulations can meet your design requirements.