Thermoplastic Extrusion for Energy and Power Electronics
ESD control, thermal resistance and electrical compliance for energy storage and electrification.
Thermoforming in the Energy Transition
At CANDEA Plastics we extrude high-performance thermoplastic sheets and rolls engineered for the energy storage (BESS), power electronics and EV charging infrastructure value chain. From inverters and DC-DC converters to lithium battery modules, our materials deliver permanent electrostatic control, elevated thermal resistance and compliance with electrical standards such as UL 94 and IEC 62368.
The energy transition demands plastic components capable of operating in high-voltage environments, safely dissipating electrostatic charges and withstanding exposure to battery electrolytes and cooling fluids (glycol). Our technical formulations enable thermoforming of BMS housings, cell separator trays, inverter enclosures and charging station covers with the dimensional precision and passive safety the sector demands.
- Lightweighting for BESS: Weight reduction in battery trays and racks versus metal solutions, optimizing system energy density.
- Fire Safety: UL 94 V-0 flame-retardant materials that contribute to passive safety against thermal runaway events.
- Precision for Power Modules: High-precision extrusion for inverter enclosures, converters and power module housings with tight tolerances.
Technical Challenges: Safety and Performance at High Voltage
ESD Protection for BMS and Power Modules
Battery Management Systems (BMS) and power modules contain sensitive electronics that control cell charging, discharging and balancing. An uncontrolled electrostatic discharge can cause communication failures, erroneous voltage readings or permanent damage to control circuits.
- Our Solution: Permanent conductive and dissipative compounds (ABS, PP) with controlled surface resistance in the range of 10³ to 10⁹ Ω/sq, integrated into the polymer matrix to ensure stability after thermoforming.
- Benefit: Reliable and homogeneous ESD protection in BMS housings, cell trays and module separators, compliant with ANSI/ESD S20.20 and energy industry OEM requirements.
Thermal Management near Batteries and Inverters
Plastic components near high-voltage battery packs and power inverters are subjected to elevated continuous operating temperatures and thermal spikes during fast-charge cycles. Deformation or loss of mechanical properties can compromise electrical insulation and assembly integrity.
- Our Solution: Modified polymers with elevated Heat Deflection Temperature (HDT) and Vicat softening point, formulated to maintain dimensional stability in continuous operating environments above 100 °C.
- Benefit: Housings and enclosures that retain dimensional tolerances and electrical insulation properties throughout the system's service life, even under aggressive thermal cycling.
Fire Safety and Chemical Resistance
In energy storage and electrification applications, plastic materials must meet strict flammability ratings and withstand exposure to lithium battery electrolytes (organic carbonates, LiPF₆) and glycol-based cooling fluids.
- Our Solution: Flame-retardant materials with UL 94 V-0 rating, compliant with IEC 62368 for information technology and audio/video equipment, with chemical resistance validated against electrolytes and glycol.
- Benefit: Certifiable passive safety that minimizes fire propagation risk in thermal runaway events, and guaranteed chemical durability in contact with battery system fluids.
Technical Material Catalog for Energy
We develop formulations that balance electrical safety, thermal resistance and ESD control for each stage of the energy value chain.
| Material Family | Key Properties | Typical Applications |
|---|---|---|
| Conductive ABS ESD | Stiffness, impact resistance, 10⁴ - 10⁶ Ω/sq protection. | BMS housings, control module enclosures, power electronics handling trays. |
| PP ESD (Polypropylene) | Superior chemical resistance to electrolytes and glycol, low density, toughness. | Battery cell separator trays, module storage containers, fluid-contact components. |
| High-Heat Polymers | High HDT, dimensional stability under aggressive thermal cycling. | Inverter enclosures, DC-DC converter housings, thermal management shields. |
| Flame-Retardant (UL 94 V-0) | Self-extinguishing, UL 94 V-0 and IEC 62368 compliance. | Electrical equipment housings, charging station enclosures, distribution panels. |
| Chemical-Resistant Compounds | Resistance to organic carbonates, LiPF₆, glycol and detergents. | BESS rack trays, electrolyte-contact components, cooling circuit parts. |
CANDEA Materials for this sector
ABS ESD Conductivo CA-447
CA-447
Compuesto de acrilonitrilo-butadieno-estireno (ABS) con protección ESD permanente en el rango disipativo. Combina alta resistencia al impacto con excelente estabilidad dimensional y un amplio rango de temperatura, lo que lo hace ideal para la fabricación electrónica y para entornos industriales exigentes, y permite fabricar en cualquier color.
View all materialsABS ESD Disipativo CA-586
CA-586
Compuesto ABS con protección ESD extendida que cubre rangos conductivo y disipativo. Su amplio espectro de resistividad de 10³ a 10⁸ Ω/sq ofrece blindaje electrostático versátil para ensamblaje, pruebas y packaging electrónico.
View all materialsMezcla PS-PE ESD CA-224
CA-224
Mezcla de poliestireno y polietileno con protección ESD conductiva. Una solución económica que combina buen equilibrio mecánico con disipación electrostática fiable, diseñada para packaging electrónico de alto volumen y manipulación automatizada de componentes.
View all materialsHDPE ESD Conductivo CA-755
CA-755
Polietileno de alta densidad (HDPE) con protección ESD conductiva y excepcional resistencia química. Diseñado para entornos agresivos donde la exposición a químicos, disolventes o electrolitos exige materiales que combinen seguridad electrostática con durabilidad a largo plazo.
View all materialsHIPS ESD Conductivo CA-140
CA-140
Poliestireno de alto impacto (HIPS) con protección ESD conductiva. Una solución de referencia para packaging electrónico, que combina excelente termoformabilidad y resistividad consistente con la rigidez y resistencia al impacto necesarias para líneas de manipulación automatizada.
View all materialsPET ESD Conductivo CA-1004
CA-1004
Tereftalato de polietileno (PET) con protección ESD conductiva y alto módulo de flexión. Ofrece estabilidad dimensional de precisión y resistencia mecánica para aplicaciones electrónicas exigentes donde tolerancias estrictas y resistencia térmica son esenciales.
View all materialsApplications Across the Energy Value Chain
From in-line protection to final parts in the end product.
Energy Storage (BESS)
Battery Energy Storage Systems (BESS) require materials that combine ESD protection, chemical resistance to electrolytes and fire safety. Our thermoplastics enable manufacturing of separator trays, module housings and racks with the reliability demanded by grid-scale installations.
- Lithium battery cell and module separator trays.
- Battery Management System (BMS) housings with ESD protection.
- Rack covers and frames with UL 94 V-0 rating.
Power Electronics & Inverters
Inverters, DC-DC converters and power modules generate intense heat and require enclosures with high thermal stability, electrical insulation and ESD protection. Our high-heat polymers and conductive materials provide the exact combination of properties for these demanding environments.
- Solar and storage inverter enclosures.
- DC-DC converter and power module housings.
- Shields and insulators for busbars and high-current connections.
Charging Infrastructure & Electrification
The expansion of EV charging infrastructure demands materials compliant with electrical standards (IEC 62368, UL 94) that withstand weathering, UV radiation and public-use conditions. Our solutions enable manufacturing of charging post housings, distribution covers and interface panels with certifiable durability and safety.
- External housings for AC and DC fast-charging stations.
- User interface panels and distribution covers.
- High-voltage cable and connector protectors.
Why choose CANDEA Plastics in Energy?
Beyond plastic extrusion, we are your partner in innovation and material development.
ESD and Electrical Safety Specialists: We advise on the optimal resistivity range (conductive vs. dissipative) and the appropriate flammability rating for each energy application.
Validated Formulations: Materials tested against lithium battery electrolytes, glycol cooling fluids and aggressive thermal cycles specific to the sector.
Regulatory Compliance: Materials compliant with UL 94, IEC 62368, REACH and RoHS, facilitating final part certification.
Total Traceability: Lot control from raw material to the final roll or sheet, essential for quality audits in energy infrastructure projects.
Agility and Flexibility: Ability to develop custom formulations, adjust thicknesses and supply in roll-fed or sheet-fed format according to production needs.
Ready to take your project to the next level?
Contact our experts to meet your technical and regulatory requirements.