CREDIT: SEKISUI KYDEX
Ray Products and SEKISUI KYDEX joined forces to eliminate unnecessary manufacturing processes and material selections that require secondary finishing processes. The collaboration between Ray Products, the OEM, and SEKISUI KYDEX originated from a shared vision of developing a material solution that would exceed the demanding requirements of the DC block housing application in the electric vehicle (EV) charging sector.
Ray Products recognized the innovation potential not only in material selection but also in advanced processing techniques that would simplify production and reduce costs. With over 75 years of experience, Ray Products has specialized in designing custom thermoformed solutions, focused on optimizing material selection, manufacturing processes, and product fitness for use. Their customer-centric approach ensures every project is crafted to meet stringent requirements while maximizing quality and durability.
Traditionally, various manufacturing processes are used in the development of EV charging stations (DC block), such as injection molding, structural foam, reaction injection molding (RIM), and sheet metal for equipment covers. However, these methods can either fail to meet the stringent outdoor requirements or require secondary finishing processes. Ray Products collaborated with the SEKISUI KYDEX appLab and designLab Innovation Centers and engaged their R&D teams to develop KYDEX 1100UV—an innovative material that meets UL 94 V-0 flammability and UL 746C F1 weather ability requirements while providing UV resistance, durability in extreme conditions, and in-mold color, eliminating the need for painting.
This collaborative effort was guided by Ray Products' goal to push the boundaries of what's possible in custom thermoforming, enabling the replacement of traditional materials like metal with durable, aesthetically versatile thermoplastics.
From material selection to streamlined assembly, Ray Products demonstrated its role as a strategic partner capable of delivering end-to-end solutions that support the evolving needs of the EV charging market.