Evolution of Grease Formulation for EV

Understanding the Unique Requirements for Electric Vehicles 

Many of the components in electric vehicles are distinctly different from vehicles with internal combustion engines (ICEs). One of the primary differences is the drivetrain. Unlike traditional ICE vehicles, EVs rely on electric motors which operate at higher RPMs and temperatures. As such, grease used on electric motors must withstand higher temperatures for smooth and durable motor performance. Below is a list of common grease requirements unique to EV. 

High Thermal Stability 

Grease formulations for electric vehicles require high thermal stability to perform under the elevated temperatures of electric motors. Improvements in base oil selection and additives are addressing these challenges effectively. 

Low Noise & Vibration 

Electric vehicles are extremely quiet in comparison to their ICE counterparts. Because of this, EV vehicle components, such as bearing and gears, are expected to exhibit superior noise and vibration reduction properties. EV-specific greases are formulated to minimize friction and dampen vibrations, thus promoting a quieter and more comfortable driving experience. 

Electrical Conductivity 

Conductivity is an important consideration for EV greases. To prevent potential electrical malfunctions or interference, specialty conductive greases are formulated to dissipate electrical charges, and prevent static build-up and electrical arcing in the drivetrain. 

Environmentally Friendly Formulations 

Given the overarching goal of sustainability in the e-mobility sector, there is an increasing emphasis on developing environmentally sustainable grease formulations. Manufacturers are focusing on biodegradable and non-toxic chemistries to reduce the ecological footprint and ensure greener disposal options. 

Longer Service Intervals 

Electric vehicles generally require less maintenance than conventional cars. Because of the longer maintenance cycles, greases are being formulated to offer extended service intervals, reducing maintenance costs and contributing to hassle-free ownership for EV owners. 

Compatibility With New Materials 

Electric vehicles are using new materials that reduce weight and enhance EV efficiencies. Grease formulations must be compatible with these new materials to ensure their long-term performance and prevent adverse interactions. 
 

Regenerative Braking Considerations 

Electric vehicles commonly use regenerative braking systems, which convert kinetic energy into electrical energy during deceleration. Greases used in the braking system are formulated to handle the unique requirements of regenerative braking, such as quick starts and stops and material compatibility. 

Afton Grease Additive Solutions 

Afton Chemical is continuously innovating performance additive technologies to meet the changing demands of the market. Afton can help you achieve high-temperature resistant, low-noise, electrically conductive grease formulations that ensure the smooth, efficient, and reliable operation of electric vehicles. Afton additives demonstrate broad compatibility with other components, base oils, and thickeners, including lithium and calcium-based thickeners. Contact us today to speak with a technical representative about your formulation needs. 

Multifunctional Additive Packages 

Streamline your formulation with Afton’s multifunctional grease additives. HiTEC® 552H and HiTEC® 553 can be used to produce high temperature, multipurpose greases with excellent extreme-pressure and anti-wear protection. 

High Temperature Components 

Afton additives help you meet the challenges of formulating a high temperature grease. HiTEC® 637 is a functional boronated succinimide dispersant that improves the structural stability of grease under high heat, while HiTEC® 55562 improves oxidation resistance and has a synergistic positive effect on high temperature resistance. 

Friction Modifiers 

Afton friction modifiers provide added lubricity to grease formulations to help reduce noise and vibration. Afton offers ashless, phosphorus-based friction modifiers with HiTEC® 059 and HiTEC® 301, and HiTEC® 7133 glycerol monooleate.