E-drives

Modern e-drives and hybrid transmission systems rely on oil-based cooling and lubrication to manage thermal and frictional loads. New lubricants have emerged to meet the challenges of higher speed operation, but these fluids are even more chemically aggressive than their predecessors. This means that sealing materials must be more robust now than ever before. Tecnoflon® FKM elastomers provide reliable sealing performance across a broad temperature range, maintaining sealing performance at low temperature and resisting degradation at elevated temperatures. In comparison with conventional elastomers, Tecnoflon^Ⓡ FKM offers superior chemical resistance and longer service life, and its resistance to both ATF and e-mobility fluids ensures reliable performance in both BEV and HEV architectures.   

As high speed e-motors are designed for increasingly high voltage systems, they are placing new demands on bearing systems. Parasitic voltage from traction motors flows through bearings and results in electro-corrosion. Syensqo supports e-motor reliability with Ryton® PPS, KetaSpire® PEEK, and AvaSpire® PAEK for overmolded bearing insulation and electrical protection. For bearing cages, Amodel® PPA and KetaSpire® PEEK provide an ideal balance of fatigue strength, chemical resistance, and friction and wear performance. Fomblin® PFPE lubricants can further enhance the long-term performance of bearings by maintaining consistent viscosity over broad temperature ranges. They can even be formulated to provide conductivity for further protection against electro-corrosion. Together, these solutions help extend bearing lifetime, prevent electrical pitting, and improve overall drivetrain efficiency.   

As e-drives and hybrid transmissions integrate compact gear designs and move towards more quiet gearing, planetary gear sets are increasingly common. The axial loads generated by these gearsets must be managed efficiently. Traditional metallic needle bearings can be replaced by high-performance polymer thrust bearings and washers to reduce space, weight, and frictional losses. Torlon® PAI and KetaSpire® PEEK offer outstanding compressive strength, wear resistance and dimensional stability under high PV conditions. These materials enable thinner components, the option to integrate oil groove designs and anti-rotational features, and enable part integration to support lightweighting, improved lubrication, better NVH performance, and higher system efficiency. The result is a lighter, more compact drivetrain with increased efficiency 

Differential assemblies require materials that combine mechanical strength, thermal stability, dimensional precision, and resistance to aggressive transmission fluids. Amodel® PPA provides a robust solution for differential spacers and integrated shells by combining high ductility with outstanding property retention and stability. Metal replacement in these components brings down total cost of ownership via part consolidation, and the increased ductility versus metal allows for easier assembly. The end result is reduced weight, simplified assembly, and lower total system cost without compromising performance. 

Oil cooled e-drives and hybrid transmissions require cooling line materials that can withstand continuous exposure to aggressive ATF and e-mobility fluids at elevated temperatures. Ryton® XE PPS is engineered specifically for these challenging environments. It offers best-in-class chemical resistance to modern transmission fluids and retains excellent mechanical strength and dimensional stability over long service intervals. It exhibits low moisture uptake and high thermal stability, which enables leak-free coolant components that resist creep and warpage. In addition, it has strong electrical properties and low flammability, making it an ideal solution for integrated oil-cooled drivetrain architectures where reliability, lightweighting, and long-term durability are a priority. 

Automatic and DCT hybrid transmissions often use mechanical face seals (seal rings) to maintain oil pressure within rotating couplings. These components must resist very high temperatures, aggressive ATF exposure, and sustained mechanical loading, all while maintaining tight leakage control. Torlon® PAI and KetaSpire® PEEK exhibit extremely high compressive strength, best-in-class thermal resistance, low creep, and outstanding dimensional stability. Both materials have high ductility and can be opened to snap around a shaft, providing assembly advantages. Their excellent wear properties support long-term reliability, reduced friction, and improved transmission efficiency in demanding hybrid architectures. 

Hybrid automatic transmissions require a torque converter to allow mechanical coupling and decoupling of the engine. Key friction and wear management components such as thrust washers and bearings, locking rings, and clutch bushings must exhibit robust chemical resistance to ATF, stable mechanical properties at temperatures approaching 150°C, and excellent dimensional stability. Torlon® PAI and KetaSpire® PEEK provide the superior wear resistance required for these thrust elements and locking components. These material solutions lower system weight, reduce frictional losses, and extend component lifetime. 

Hybrid AT and DCT systems combine hydraulic and electric actuation to ensure smooth gear changes. Components such as solenoid snouts and pins, actuator housings, check balls and shift forks must maintain tight dimensional tolerances while resisting aggressive fluids and thermal cycling. Amodel® PPA and Ryton® PPS have the right balance of electrical insulation, chemical resistance and dimensional stability for actuator housings and solenoid components. Torlon® PAI and KetaSpire® PEEK deliver extreme fatigue resistance and wear performance for dynamic elements like check balls and shift forks. These materials offer opportunities for part integration, weight reduction, and improved NVH, contributing to reliable and efficient hybrid drivetrains 

Oil pump components need to be designed and manufactured to precise tolerances to ensure optimal performance. Ryton® PPS is well suited to  replace machined metal components in oil pump housings. It offers excellent dimensional stability under oil immersion and extreme chemical resistance. It has high stiffness and creep resistance, which help to maintain tight tolerances and sealing integrity over extended service life, even during thermal cycling. Ryton^Ⓡ PPS serves as a lightweight metal replacement option and supports complex, thin-walled, injection molded geometries. This allows for part consolidation and improved packaging in compact electrified drivetrain systems. The result is a durable, cost-effective solution that maintains consistent pump performance and reliable fluid delivery.