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Ahead of the pack

Covestro polycarbonate blend revs up electric motorcycle

Ahead of the pack

Advances in battery technology are making more eco-friendly modes of transportation possible. One company leading the charge is Alta Motors, a manufacturer of high-performance electric motorcycles.

The battery pack and subframe of the Redshift electric motorcycle utilize Makroblend® polycarbonate blend resins from Covestro. (Photo credit: Alta Motors)
The battery pack and subframe of the Redshift electric motorcycle utilize Makroblend® polycarbonate blend resins from Covestro. (Photo credit: Alta Motors)

Task

Alta Motors developed the Alta Pack, a custom, energy-dense battery pack for its Redshift MX and SM electric motorcycles. The Alta Pack stores 5.8 kWH into 31.5 kilograms with a maximum output of 350V, requiring materials that would provide structure and tolerate impact.

Challenge

The battery housing material must be able to handle different kinds of wear and tear: the sun, weather elements, dirt and more. There’s also risk of impact from dropping the removable battery or the motorcycle hitting the ground. Covestro assisted with material selection, as well as color matching.

Solution

The Alta Pack features an aluminum casting with black textured covers injection molded from Makroblend® UT5207 polycarbonate/polybutylene terephthalate (PC+PBT) blend and Makroblend® UT403 polycarbonate/polyethylene terephtalate (PC+PET) blend. Makroblend® resins offer chemical resistance, impact resistance, durability, ease of processability and the ability to be bonded to a metal substrate. The core of the Redshift subframe features Makroblend® UT6007 PC+PBT blend for exceptional durability.

Case Profile

Alta Motors

Alta Morors 

Supplier

Covestro LLC

Industry

Transportation

Application

Redshift MX and SM electric motorcycles

Makroblend® (PC+PBT; PC+PET blend) - family of ultra-tough materials

Makroblend® polycarbonate blend resins in the battery housing offer durability, chemical resistance and impact strength, all important attributes for an electric motocycle.

The top battery cover contains Makroblend® UT5207 PC+PBT blend for dimensional stability, meaning it can withstand heat or humitidy, to protect the electronics mounted inside.

The bottom battery cover utilizes Makroblend® UT403 PC+PET blend, which is UL746C f1 rated, meaning the material withstands exposure to UV and water.

Makroblend® UT6007 PC+PBT blend provides the subframe with exceptional low-temperature impact strength to withstand everyday wear and tear.

The selected materials offer easy release from the mold for ease of processing.

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