COMPOUNDS | AUTOMOTIVE
fibres under the Tepex brand intended for battery housings and related components, which passes standard thermal runaway tests for battery housings in EVs with wall thicknesses of 1.5 mm without swelling. The material, significantly lighter than steel and aluminium, is also available in an electromag- netically shielding version. Envalior has also devel- oped several solutions capitalising on hollow profile hybrid technology (HPH) in lightweight construction whereby metallic hollow profiles are reinforced and functionalised with plastic compounds like Durethan or Akulon. This offers weight savings of up to 35%, enables high-precision production with low toler- ances, and results in rework-free parts that often have better damping and acoustic behaviour than corresponding parts made of metals. “[EVs] rely on lithium-ion battery cells for storing and delivering power, and they come with a significant weight increase,” said James Brasch, Marketing Manager, Transportation & Outdoor High Performance at Formerra. “Balancing weight concerns with design efficiency and performance needs makes lightweighting more difficult in EVs than in traditional vehicles while being an even higher priority. Fortunately, materials and design advancements have enabled significant weight reductions without compromising performance or safety. This combination helps EV designers overcome the price and perfor- mance gaps between electric and gasoline vehicles. Unibody design is where the body and chassis form a single, integrated unit. Instead of
bolting a separate body onto a frame,
Above: Avient says the
evolution of battery enclosures exemplifies the need to adopt lightweight and high- performance materials
the vehicle’s body acts as the main load-bearing structure. Making the battery pack part of the structural framework of the chassis can help create a more lightweight vehicle without compromising structural capacity while incorporating materials such as carbon fibre-filled nylon can further reduce weight. Unibody construction is more rigid and lighter than traditional body-on-frame design, helping EVs reduce metal usage in bolts, clips, and other fasteners. As an added benefit, they enable streamlined manufacturing for better noise, vibration, and harshness characteristics.” Hank Crawford, Market Development Manager,
Transportation at Avient Advanced Composites and PlastiComp, said: “A growing trend and crucial aspect of EV technology is improving battery pack energy density, measured in watt-hours per kilogram (Wh/Kg), which defines powertrain
52 COMPOUNDING WORLD | August 2024
performance. OEMs are focused on designing structural battery packs with integrated battery cells to achieve higher energy densities. This involves optimising various components for weight and performance, such as battery cells, relay boxes, connectors, modules, and battery management systems, all as an integrated solution that contrib- utes to the overall vehicle structure. To enhance battery pack energy density, manufacturers are investigating and transitioning to lighter-weight materials, such as engineered polymers and composite materials, to provide structural integrity traditionally found in metal components.” He continued: “The evolution of battery enclo-
sures exemplifies the need to adopt lightweight and high-performance materials. Modern enclo- sures are integrated structural components of the vehicle designed to enhance safety, performance, and efficiency. They safeguard the battery, provide fire protection, and shield the vehicle from electro- magnetic interference. The use of lightweight, fibre reinforced thermoplastic materials extends beyond the battery enclosure to other components. Utilising composites enables manufacturers to significantly reduce vehicle weight while maintaining structural rigidity and durability, ultimately leading to im- proved energy efficiency and driving dynamics.”
EMI shielding Christine Van Bellingen, Business Development Manager, Conductive Compounds at Witcom Engineering Plastics (part of the Wittenburg Group), said: “Weight reduction is the biggest push for Tiers and OEMs to move forward to metal replacement in EVs, especially for ECU [electronic control unit] and inverter housings. After tests our new generation of EMI [electromagnetic interfer- ence] shielding compounds provided some very good results. Our grades can fulfil the adequate dB [decibel] attenuation targets at high and lower frequencies and possess outstanding flame-retard- ant properties. PA, PBT, PPS and PC-based EMI shielding compounds are available, and other grades are under development.” For almost 20 years Witcom has been a major supplier of radar absorption compounds used to enhance ADAS radar sensor performance and avoid ghost targets. In addition to PA, PP, PBT, PC and TPE radar absorption grades for RF absorbers, brackets, funnels and housings, the company now also offers radar absorbing recycled compounds. “In recent years, Witcom has shifted its lubricated compound developments towards PTFE-free solutions due to the coming regulatory changes,” said Van Bellingen. “Our compound portfolio now
www.compoundingworld.com
IMAGE: AVIENT
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