Serigraph uses Makrofol® SR906 for durable EV charger
Electric vehicle charging system (EVCS) providers expect their demand to grow significantly by the year 2030, so they’re recruiting companies like Serigraph Inc., USA, a leading provider of eye-catching corporate branding signage and point of sale installations, to help create high-impact branding for their charging stations.
Electric vehicles (EVs) typically get their battery charge at outdoor stations or installations, and the actual EV charging cords are handled and used constantly in everyday operations. This means that every part of the electrical charging unit must be exceptionally weather- and UV-resistant and flame retardant, yet also stand up to repeated use, daily wear and tear, and scratching.
The challenge Serigraph faced was how to create an EV charger part from thermoplastic that is as durable as metal alternatives, but at the same time features a glass-like appearance and feel, along with a wide range of design possibilities for the effectful integration of the customers’ logo.
The component needed to be manufactured using film insert molding (FIM) processing, without any trade-off in toughness, chemical resistance or weathering performance. Ideally, this new piece of electric vehicle supply equipment would also be more environmentally friendly, replacing metal parts with lightweight alternatives with lower CO2 emissions.
Our partnership with Covestro was key to the success of this application, with the expertise of the Covestro team and their film solutions for injection molding. The decorative and durability requirements of this automotive part made Makrofol® SR906 the obvious solution.
Makrofol® SR906 turned out to be the optimal solution for Serigraph when manufacturing an EV charger part using FIM processing.
This polycarbonate (PC) acrylic film is specifically engineered for FIM processing, where the film is placed into the mold at the same time as the resin is injected. Combining these two steps allows for attractive graphic branding of the OEM’s logos. What’s more, Makrofol® SR906 could accommodate functional touch capabilities. It can be adapted to a specific surface feel, from glossy to textured and enable backlighting effects.
In addition to the design freedom and functionality of the material, Serigraph was particularly impressed by the improved resistance to weather influences and chemicals in combination with impact resistance. Makrofol® SR906 is a clear transparent extruded polycarbonate film with an acrylic functional layer. The acrylic on the top surface offers improving scratch resistance while the polycarbonate back surface provides excellent printability and can be back molded with polycarbonate resin in FIM process.
The combination of the acrylic functional layer and the polycarbonate layer overcomes the low impact resistance of acrylic films. Additionally, this PC film has good heat resistance and excellent impact strength.
In this way, Makrofol® SR906 helps to ensure that decorative parts for electric vehicle charging cord are durable and retain their attractive appeara.
Key benefits
- Tough and strong: PC films are durable and impact resistant.
- Weather resistant: Makrofol® SR906 offers enhanced weatherability and scratch resistance.
- Optimal haptics: Makrofol® SR906 can be tuned for a glass-like feel and include touch controls.
- Design flexible: PC films offer excellent printability and various seamless surfaces and colors.
- Flame retardant Polycarbonate is naturally temperature resistant.
