LANXESS and Kautex Textron present polyamide 6 viable plastic enclosure for high-voltage batteries in EVs


Technical plastics equivalent to polyamide 6 supply quite a few advantages for the design of battery enclosures for electrical autos by way of sustainability, manufacturing prices, weight financial savings and economical useful integration, for instance. Nevertheless, there have been doubts as as to whether these massive and complicated parts are additionally in a position to meet the very demanding necessities in relation to mechanical power and flame-retardant properties.

Kautex Textron and LANXESS have now carried out a complete examination of this utilizing a collectively developed know-how demonstrator constructed from polyamide 6. LANXESS was answerable for the fabric growth and Kautex Textron for the engineering, design and the manufacturing means of the demonstrator.

The near-series demonstrator passes all mechanical and thermal assessments which might be related for such enclosures. As well as, options for the thermal administration and leak tightness of the enclosure, for instance, have been developed. This all has confirmed the technical feasibility of those security parts, that are advanced and topic to excessive ranges of stress.

— Dr. Christopher Hoefs, Undertaking Supervisor e-Powertrain at LANXESS

IMG_Batteriegehuse-Demonstrator Sitecore Image Standard

Crush take a look at within the y path: The outcomes of the simulation match these of the bodily part take a look at very nicely. Photograph: Kautex

An enclosure prototype is at the moment being street examined in a take a look at car to confirm its suitability for day by day use.

We’re at the moment collectively tackling the primary series-production growth tasks with automotive producers with a view to implement the brand new know-how in collection manufacturing.

—Felix Haas, Director Product Growth at Kautex Textron

Calculations discovered that the carbon footprint of the plastic enclosure is greater than 40% smaller in comparison with an aluminum design. The decrease power use within the manufacturing of polyamide 6 in contrast with metallic in addition to different elements—such because the omission of time-consuming cathodic dip portray to stop corrosion the place metal is used—assist to attenuate the carbon footprint, mentioned Hoefs. The thermoplastic part design additionally makes recycling the enclosure simpler in contrast with thermoset supplies equivalent to sheet molding compounds (SMC), for instance.

The assessments on the know-how demonstrator have been carried out in accordance with internationally acknowledged requirements for battery-powered electrical autos equivalent to ECE R100 from the Financial Fee for Europe or the Chinese language commonplace GB 38031. The massive-format all-plastic enclosure, which measures round 1,400 millimeters in each size and width, demonstrated its efficiency in all related assessments.

For instance, it meets the necessities of the mechanical shock take a look at, which is used to look at the part’s habits within the occasion of extreme shocks, and of the crush take a look at, which the builders use to look at the resistance of the battery enclosure within the occasion of sluggish deformation. The outcomes of the drop and vibration assessments have been additionally optimistic, as have been these of the underside impression take a look at. This take a look at examines the soundness of the batteries, that are largely accommodated within the car flooring, within the occasion of a floor contact of the car construction or of impacts from sizeable stones.

All take a look at outcomes corroborate the earlier simulations and calculations. A important failure of the plastic enclosure wouldn’t have occurred in any of the load instances, mentioned Haas. The demonstrator additionally proved its resistance to exterior sources of fireside beneath the car in accordance with ECE R100 (exterior fireplace).

The demonstrator was developed primarily based on the aluminum battery housing of a mid-size electrical car and designed for mass manufacturing. It’s manufactured in a single-stage compression molding course of with a molding compound primarily based on the polyamide 6 compound Durethan B24CMH2.0 from LANXESS and doesn’t require any additional rework.

Crash-relevant areas are specifically bolstered with domestically positioned blanks constructed from the continuous-fiber-reinforced, polyamide 6-based composite Tepex dynalite 102-RGUD600.

In contrast with an aluminum design, there’s a weight saving of round 10%, which is advantageous for the vary and due to this fact the carbon footprint of the car.

The mixing of capabilities—such because the fasteners, reinforcing ribs and parts for the thermal administration—reduces the variety of particular person parts considerably in contrast with the metallic design, which simplifies meeting and logistical effort and reduces manufacturing prices.


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