Impact-resistant polycarbonate from Covestro utilized in Lear Corporation battery chargers

Novi, MI, September 15, 2015 — In the U.S., the electric vehicle market continues to experience significant growth, accounting for 39 percent of global electric vehicle sales in 2014, according to the International Council on Clean Transportation. Product innovation is one of the key factors driving EV adoption, as advances in charging equipment and infrastructure are encouraging more U.S. drivers to choose sustainable options. Polycarbonates from Covestro – formerly Bayer MaterialScience – are playing a critical role in the development of effective, cost-efficient charging equipment for electric vehicles.

Covestro provided impact-resistant material capable of sustaining demanding mechanical force and environmental elements for the latest battery chargers offered by Lear Corporation, a leading global supplier of automotive seating systems and electrical power management systems. The third-generation Lear portable charger is carried in the trunk of plug-in vehicles, including extended-range and fully electric vehicles, and offers drivers increased strength and safety. It passed all drive-over tests and was shown to protect all live parts even under severe weight loads. The product went into production in July 2015 and is expected to be commercially available next year.

The charger’s body is injection molded from Makrolon® 2607 black polycarbonate and is approximately 3mm thick with honeycomb reinforcement for added durability. It is considered one of the most compact chargers on the market and is classified as a Level 1 (120V AC) or Level 2 (240 V AC).

“We worked closely with Lear to identify the right materials and process to improve the quality of the part and optimize production,” said Ignacio Osio, Key Growth Programs Manager, Polycarbonates, Covestro. “Our team of engineers collaborated seamlessly to provide extensive mold design and welding assistance that helped to resolve early cosmetic and manufacturing challenges.”

In addition to on-site processing support, Covestro provided thorough color-matching support to satisfy the optics requirements of the charger’s LED lens, which is formed from clear Makrolon® polycarbonate.

“Electromobility requires material and process innovation,” said Terry Davis, principal engineer at Covestro, who served as one of the product’s lead designers. “Covestro is pleased to work with Lear to offer value-added electric vehicle solutions.”

Attendees at The Battery Show, Sept. 15-17, can visit Covestro’s booth (#2045) for more details about Covestro’s material solutions for electric vehicles.

About Covestro LLC:

Covestro LLC is one of the leading producers of high-performance polymers in North America and is part of the global Covestro business. Covestro manufactures high-tech polymer materials and develops innovative solutions for products used in many areas of daily life. The main segments served are the automotive, electrical and electronics, construction and sports and leisure industries. The Covestro group has 30 production sites around the globe and employed approximately 14,200 people at the end of 2014. Covestro is a Bayer Group company.

For more information about Covestro’s polycarbonates, call 1-800-662-2927 or visit

Covestro Contact:

John Skabardonis, Phone: +1 412-413-5444

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This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG or subgroup management. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s and Bayer’s public reports which are available on the Covestro website at as well as on Bayer AG’s website at Covestro assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

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