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HomeNEWSArticlesNovares Develops Novel BEV Cooling Plate With Plastic/Metal Bonding Technology from DuPont

Novares Develops Novel BEV Cooling Plate With Plastic/Metal Bonding Technology from DuPont

Novares Develops Novel BEV Cooling Plate With Plastic/Metal Bonding Technology from DuPont

The global plastic solutions provider leaps ahead with its Hybrid Cooling Plate for improved battery performance and durability.

Automotive Tier 1 Novares and DuPont Mobility & Materials are co-developing a new hybrid plastic/metal cooling plate that will help OEMs extend the range and lifetime of their EV batteries. One key to this new project is the patented plastic/metal bonding technology developed at DuPont’s technology center in Meyrin, Switzerland.

Novares is a global designer and manufacturer of complex components and systems for its OEM customers. “In collaboration with application development engineer Vincent Descombes, and the experts from DuPont’s Centers of Excellence for automotive electrification and assembly techniques, the engineers at our Powertrain China Skill Center were able to overcome technical challenges and provide a disruptive solution for EV battery cooling,” said Laurent Vanholme, Expert Powertrain Components at Novares. “We were able to master the difference in thermal expansion between the metal and plastic parts, and re-engineer the product to be processed with conventional welding.”

Developed at the company’s Automotive Electrification Center of Excellence, the plastic/metal bonding technology patented by DuPont enables the efficient manufacturing of a wide range of components for automotive and other industries. The technology was initially developed to support companies intent on replacing metal EV battery cooling plates with hybrid designs that are more economical to produce and that also better manage EV battery temperature. Novares confirmed that its cooling plates meet industry requirements and enable cost reduction versus all-metal alternatives.

Key to the success of these hybrid cooling plates is DuPont Zytel HTN high-temperature nylon, which withstands the temperatures and aggressive chemicals in these applications and has excellent flow properties that enable complex designs.

Also key is DuPont’s patented bonding technology. This technology – which can be integrated into the injection molding process – enables quick hot plate welding of aluminum to injection-molded parts made of Zytel or Zytel HTN. Although the metal and the thermoplastics have different coefficients of thermal expansion, the bond between these disparate materials is strong enough to withstand extreme temperaturesand aggressive chemicals.

“Congratulations to Novares for this novel development, which comes at a critical time for demand growth of BEVs. Novares’ work will help OEMs offer consumers vehicles that drive farther, with batteries that last longer,” said Gabe Knee, Marketing Manager for Vehicle Electrification at DuPont Mobility & Materials. “Our plastic/metal bonding technology is a game changer for manufacturers of automotive components, and will quickly find uses in other industries.”

For additional information about DuPont Mobility & Materials, visit



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