INNOVATION | THERMOPLASTIC COMPOSITES
structure is carried out using continuous fibre-rein- forced thermoplastic composites of Lanxess’ Tepex Dynalite brand. The process enables shorter and more economical cycle times than the processes in which steel or aluminium are processed. Housings for high-voltage batteries are currently primarily made of extruded steel or aluminium profiles. Depending on the vehicle class, the housing length and widths can be well over 2,000 and 1,500 mm, respectively. The size, the number of components and the numerous manufacturing and assembly steps make metal housings very cost intensive. For example, complex structures made from strand press profiles require many secondary work steps such as welding, punching and riveting. In addition, the metallic components must be protected against corrosion in an additional process step by cathodic dip coating. “Plastics, on the other hand, can fully exploit their design freedom,” says Hoefs. “By integrating functions, such as fasteners and thermal manage- ment components, the number of individual components of a battery housing can be greatly reduced. This simplifies assembly and logistical effort, which reduces production costs.” Plastics are
also corrosion-resistant, as well as electrically insulating which ensures that there is a reduced risk of the system short-circuiting. The low density of plastics and their potential for lightweight construc- tion lead to significantly lighter housings, which benefits, among other things, the travel range of electric vehicles. High-voltage battery housings must meet a
variety of highly demanding technical require- ments. For example, they must be stiff and strong and yet be able to absorb a significant amount of energy in the event of a crash. This is tested through mechanical shock and crush tests. The housings must also be flame-retardant in the event of a vehicle fire or thermal run-away of the electri- cal cells. Finally, the housings must be integrated into the vehicle structure. Lanxess has also optimised Tepex continuous-
fibre-reinforced thermoplastic composites for the production of structural components that form part of driver assistance systems. One example is a bracket for a battery that supplies electricity to the highly automated driver assistance system ‘Intel- ligent Drive’ in the Mercedes-Benz S-Class in the event of a sudden power failure. The bow-shaped
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High quality recycled plastic that has been collected from coastal areas at risk of ocean plastic pollution.
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