E.Stall Esslingen uses Covestro's flame retardant Bayblend products to design its lithium-ion battery modules. It has been using the electric racing cars it produces to participate in the German student equation, a major event held annually at the Hockenheim Circle.


The traction battery of the car has a high design requirement - this is also the most important part of the race. It determines whether the driver has enough energy to win the game.


Since the 2018 season, Covestro has provided the E.Stall Esslingen team with flame retardant materials for the manufacture of batteries. At its Leverkusen pilot plant, plastics manufacturers extruded sheets from the PC + ABS mixture Bayblend to produce frames and supports for their battery modules. These modules are based on lithium ion battery cells in the form of "bags".


Safety material for safety batteries


The various disciplines of the Battery Design Department of the University of Applied Sciences in Esslingen complement each other. In addition, the student equations specify certain design requirements for students. In addition to actively monitoring and controlling the battery, the student equation rules explicitly require the use of flame retardant materials.


Raphael Raff, head of the high-pressure subproject at E. Stall Esslingen, said: “We are very pleased that Covestro has supported our work with polycarbonate blend plates again in the 2019 season, allowing us to easily process batteries.”


The racing team selected the PC + ABS blend with Coxtron's Bayblend product experts. Its density is reduced by about 10% compared to the previous year. At the same time, mechanical, electrical and thermal properties are also high.


Designers are looking for materials that are easy to machine in large-scale production, but that also meet the automotive manufacturer's stringent requirements for vehicle operation.


Amorphous plastics such as polycarbonate have the advantage over semi-crystalline materials that they do not shrink significantly during injection molding and have very low water absorption. Polycarbonate is also fire resistant.

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