Renewable PC Delivers the Spark in EV Chargers

Sabic is enabling Charge Amps to manufacture electric vehicle (EV) chargers with a housing made from certified renewable polycarbonate (PC) under the ISCC Plus certification mass balance approach.

Sabic is supplying Charge Amps with its certified renewable-grade Lexan PC, supporting the EV charger provider’s commitment to develop the circular bioeconomy and help mitigate climate change issues. Sabic’s renewable PC from its Trucircle portfolio is made from second-generation bio-feedstock that is not in competition with the food chain. The new industrial process contributes to reduce CO₂ emissions in manufacturing and installation and fully meets EVSE (Electric Vehicle Supply Equipment) regulations.

EVs are an essential component of decarbonization strategies being adopted by governments and enterprises around the world. EVs are now an increasingly viable alternative to internal combustion engines (ICEs) to reduce the carbon footprint. The availability of charging facilities is recognized as one of the key factors associated with conversion to EVs.

Critical charging infrastructure

Market watcher S&P Global Mobility forecasts that around 47% of passenger vehicles delivered to drivers in 2030 will be battery EVs, with fully electric market shares of 46% in North America, 64% in Europe, and 60% in China.

With an expected 200 million or so EVs on the road in 2030, a reliable and efficient EV charging infrastructure will be paramount to keeping these cars moving. Based on one publicly available charger per 10 to 15 vehicles, that’s up to 20 million charging stations. When private chargers are included, another market watcher BloombergNEF estimates up to 490 million charging points will be required by 2040.

50% renewable content

Charge Amps’ Dawn charger contains in the range of 50% of ISCC Plus certified bio-based renewable material from Sabic. Majed Al-Saadan, director, building & construction segment, commented: “Sabic offers selected plastic solutions from our building and construction segment that can fulfil stringent industry standards for the making of EV support equipment in terms of safety and reliability. In addition, it offers efficiency in manufacturing as well as better aesthetics compared to incumbent solutions. Together with Charge Amps, we are going one step further by cutting the carbon footprint from the production phase to support the world’s transition to an electric future.”

Lower emissions, premium look

Jonas Hellström, mechanical design manager at Charge Amps, commented: “Design, innovation, and sustainability are key priorities for Charge Amps. The bio-attributed plastic based on renewable feedstock from Sabic allows us to combine lower carbon emissions with the premium exterior design that Charge Amps is known for. We strive to be in the forefront of technology. This strategic partnership with Sabic is a natural step to being a responsible player in the EV charging ecosystem.” 

On top of sustainability gains, EV charger manufacturers can benefit from increased functional integration and design freedom. For example, inner panels and indoor cabinets and consoles can be produced from a flame retardant (FR) PC to achieve dimensional stability, impact resistance, and aesthetic finishing. Furthermore, thin-wall FR capability can help reduce weight beyond that achieved by simply replacing metal and can also free up space for additional components.

Lexan PC is durable and weather resistant and can provide manufacturing cost reductions. It enables charger makers to simplify production processes by using high-speed, high-volume injection molding, and it eliminates typical secondary operations that would otherwise be required for metals.