Covestro, LEONHARD KURZ and Sumitomo (SHI) Demag join forces to design a more sustainable EV wallbox charger
The new wallbox design demonstrator uses Covestro’s Makrolon® RE and Makrofol® material solutions in combination with design technologies from LEONHARD KURZ and injection molding technology from Sumitomo (SHI) Demag. The partners visualized together sustainable charging in a "vehicle-to-grid" concept. This means that the vehicle battery is used as a buffer storage unit that releases electricity to the grid to compensate for power fluctuations.
The wallbox design demonstrator showcases an application for the new, more sustainable Makrolon® RE polycarbonates as material solution for EV chargers. Equipped with a display, backlighting, and touch controls, the wallbox offers a wide range of design possibilities to power the future of electromobility.
“The wallbox charger of tomorrow will no longer be purely functional but will become a true design feature – visually appealing and with a range of smart capabilities. In addition, it will be designed to be produced in an efficient and resource-saving manner, leading to improvements in sustainability.”
Representing enhanced versatility both in terms of design and functionality, the wallbox design demonstrator offers a range of possibilities for technology integration. Due to their superior performance qualities, transparent Makrolon® RE polycarbonate and Makrofol® films are well-suited to backlight and sensor integration. They are compatible with in-mold decoration (IMD), film insert molding (FIM), and hot stamping production processes. Using the latest technologies from KURZ and Sumitomo (SHI) Demag, Covestro material solutions enable a streamlined manufacturing process and unlock an advanced array of functional and design possibilities.
“The wallbox design demonstrator illustrates a unique fusion of design, sustainability, and innovative technologies for stylish wallbox chargers. This combination enables a high level of individualization and design flexibility, as well as enhanced sustainability credentials.”
Demonstrating a wide range of features to power the next generation of EV chargers, the wallbox design demonstrator is a clear step forward in the evolution of lower-impact electromobility design. The wallbox anticipates a renewable electricity future with its bidirectional charging capabilities. This gives it the power to switch between charging the vehicle via a home solar system and supplying the electricity grid from the vehicle’s charged battery (V2G). With all these features, the wallbox design demonstrator confirms why using Makrolon® RE and Makrofol® is a forward-looking choice for producing EV charging applications.
“Flexibly expandable and thus cost-efficient production solution, with the core of an extremely energy-efficient and precise all-electric injection molding machine.”
Key Benefits
- Reduced CO₂ footprint Makrolon® RE is ISCC PLUS certified product with a significant carbon footprint reduction in comparison to conventional polycarbonates.
- Efficient production Made using in-mold decoration (IMD), film insert molding (FIM), and hot stamping.
- Customized design Countless design variations are possible in one production step.
- High-quality drop-in solution Makrolon® RE grades have identical high-performance properties to standard Makrolon® grades
- Preserve fossil resources Mass-balanced raw materials from biological waste and residues largely replace fossil feedstock
