BASF, the world's leading provider of materials solutions in the plastics sector, has supported RML Group in the development of an innovative, immersion-cooled battery for a high-performance hybrid hypercar that sets new performance and safety standards using next-generation plastic materials. The 800V battery features a capacity of 4.2 kWh and a discharge rate of >100C, weighing in at less than 75kg.

The extremely high-power output, especially during rapid acceleration and regeneration, requires a cooling system capable of rejecting the heat generated by the cells. To prevent extreme temperatures and ensure a more even temperature distribution throughout the pack, immersion cooling is used, which greatly improves the entire battery system’s efficiency and service life. Two BASF plastics are used in RML's battery unit.

First, there is Ultramid B3EG7 (PA6GF35) both as the housing material for the battery unit itself and in the housing of the high-voltage electrical components of the battery control system. Second, Ultramid A3EG6 EQ (PA66GF30) is used as the material for the individual battery cell holders within the battery housing.

"RML needed to explore state-of-the-art materials for battery systems to meet the mass and structural targets set by customers for high-performance applications. We worked closely in collaboration with BASF to achieve the desired properties and I look forward to working together evolving and enhancing material development with BASF on future projects.” expresses James Arkell, Head of Powertrain at RML.

Due to its extensive expertise in the new battery sector and in the field of electrical and electronic (E/E) materials, BASF managed to significantly accelerate the development of the overall battery unit.

"Our in-depth materials expertise and commitment to sustainable solutions enable us to meet customer requirements in the shortest possible time and advance electrification in the transport sector," says Jasmina Simon, plastics materials expert for eMobility.

In addition to its materials solutions, BASF also provides comprehensive services such as component simulation. Ultrasim®, for example, can be used to develop components for specific requirements, so as to create heavy-duty, efficient and lightweight customized components.