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(c) AZL. Comparison of battery casing in modular design and “cell-to-pack” design
Comparison of battery casing in modular design and “cell-to-pack” design
02.09.2022

AZL: Plastic-based multi-material solutions for cell-to-pack battery enclosures

The future of e-mobility will be determined in particular by safe battery enclosures. As batteries for electric vehicles become more performant, higher volumetric energy density plays a crucial role. If more energy is to be stored in less installation space, new material and design solutions are required. The development of suitable enclosures made of safe and highly robust lightweight materials is also required. This is a case for the Aachen Centre for Integrative Lightweight Production (AZL). A project on cell-to-pack battery enclosures for battery-electric vehicles, which has been eagerly awaited in the industry, will start in October this year there.

The future of e-mobility will be determined in particular by safe battery enclosures. As batteries for electric vehicles become more performant, higher volumetric energy density plays a crucial role. If more energy is to be stored in less installation space, new material and design solutions are required. The development of suitable enclosures made of safe and highly robust lightweight materials is also required. This is a case for the Aachen Centre for Integrative Lightweight Production (AZL). A project on cell-to-pack battery enclosures for battery-electric vehicles, which has been eagerly awaited in the industry, will start in October this year there.

The design of battery housings is crucial for safety, capacity, performance, and economics. The Cell-to-Pack project, which is starting now, will focus on developing concepts for structural components and for producing them based on a variety of materials and design approaches. The concepts will be compared in terms of performance, weight and production costs, creating new know-how for OEMs, producers and their suppliers throughout the battery vehicle value chain. Companies are now invited to participate in this new cross-industry project to develop battery enclosure concepts for the promising and trend-setting cell-to-pack technology.

The basis for the project is the lightweight engineering expertise of the AZL experts, which they have already demonstrated in previous projects for multi-material solutions for module-based battery housings. Together with 46 industry partners, including Audi, Asahi Kasei, Covestro, DSM, EconCore, Faurecia, Hutchinson, Johns Manville, Magna, Marelli and Teijin, 20 different multi-material concepts were optimized in terms of weight and cost and compared with a reference component made from aluminum. All production steps were modelled in detail to obtain reliable cost estimates for each variant. Result: depending on the concept, 20% weight or 36% cost savings potential could be identified by using multi-material composites compared to the established aluminum reference.

It is expected that the design concept of battery enclosures will develop in the direction of a more efficient layout. In this case, the cells are no longer combined in modules in additional production steps, but are integrated directly into the battery housing. The elimination of battery modules and the improved, weight-saving use of space will allow for higher packing density, reduced overall height and cost saving. In addition, various levels of structural integration of the battery housing into the body structure are expected. These new designs bring specific challenges, including ensuring protection of the battery cells from external damage and fire protection. In addition, different recyclability and repair requirements may significantly impact future designs. How the different material and structural options for future generations of battery enclosures for the cell-to-pack technology might look like and how they compare in terms of cost and environmental impact will be investigated in the new AZL project. In addition to the material and production concepts from the concept study for module-based battery enclosures, results from a currently ongoing benchmarking of different materials for the impact protection plate and a new method for determining mechanical properties during a fire test will also be incorporated.

The project will start on October 27, 2022 with a kick-off meeting of the consortium, interested companies can still apply for participation until then.

AZL schließt gemeinsam mit 46 Industriepartnern Projekt zu Batteriegehäusen erfolgreich ab (c) AZL
06.12.2021

AZL: Gemeinsames Projekt zu Batteriegehäusen mit 46 Industriepartnern

Gemeinsam mit insgesamt 46 Industriepartnern konnten mehrere, verschiedene Konzepte für Kunststoff-basierte Multimaterial-Batteriegehäuse erarbeitet werden, mit denen deutliche Einsparpotentiale bei Gewicht und Kosten möglich sind. Im Projektverlauf kristallisierten sich zwei wichtige Kernthemen heraus, die in Folgeprojekten gesondert behandelt werden sollen: Bodenaufprallschutz und Feuerbeständigkeit. Diese zwei Folgeprojekte starten am 26. Januar 2022. Ein Projekt zur Entwicklung und Realisierung von Prototypen für Mitte nächsten Jahres 2022 ist in Planung.

Gemeinsam mit insgesamt 46 Industriepartnern konnten mehrere, verschiedene Konzepte für Kunststoff-basierte Multimaterial-Batteriegehäuse erarbeitet werden, mit denen deutliche Einsparpotentiale bei Gewicht und Kosten möglich sind. Im Projektverlauf kristallisierten sich zwei wichtige Kernthemen heraus, die in Folgeprojekten gesondert behandelt werden sollen: Bodenaufprallschutz und Feuerbeständigkeit. Diese zwei Folgeprojekte starten am 26. Januar 2022. Ein Projekt zur Entwicklung und Realisierung von Prototypen für Mitte nächsten Jahres 2022 ist in Planung.

Batteriegehäuse gehören zu den Schlüsselkomponenten in E-Fahrzeugen und werden derzeit in der Regel aus Aluminium hergestellt. Genau diese Komponente analysierte das AZL in dem jetzt durchgeführten Projekt mit einem großen Konsortium aus Automobilherstellern, Automobilzulieferern, Rohstoffherstellern und Maschinenherstellern. „Der enorme Zuspruch aus der Industrie unterstreicht die Relevanz des Themas“, freut sich der Projektleiter Warden Schijve, der zudem sehr zufrieden mit dem Verlauf und den Ergebnissen ist. Schließlich lassen sich bis zu 36 % des Gewichts und bis zu 20 % der Kosten einsparen, wenn anstelle herkömmlicher Lösungen Multi-Material-Verbunde auf Basis von Kunststoffen zum Einsatz kommen.

Um zu den Ergebnissen zu gelangen, hat das AZL unter Mitwirkung seiner Partnerunternehmen, zu denen unter anderem Audi, Asahi Kasei, Covestro, DSM, EconCore, Faurecia, Formosa, Hengrui, Hutchinson, IPTE, Johns Manville, Magna, Marelli und Teijin, gehörten, zunächst fünf Subkomponenten eines Batteriegehäuses definiert: die Gehäusewanne, die Bodenschutzplatte, den Crash-Rahmen, die Querbalken und den Gehäusedeckel. Außerdem analysierten die Partner insgesamt 44 marktrelevante, existierende Serienkomponenten und Konzepte genauer und erstellten eine umfangreiche Übersicht über die verschiedenen Standards sowie Anforderungen auf nationaler, internationaler und OEM-Ebene. Prämisse dabei war, gleiche oder gar bessere mechanische Kennwerte zu erreichen als bei herkömmlichen Lösungen. So sollten beispielsweise mindestens gleiche Steifigkeiten, Sicherheiten bei seitlichem Aufprall, EMI-Abschirmung sowie Flammschutz vorhanden sein. Um nun die alternativen Lösungen zu ermitteln, entwickelte das AZL 20 Designkonzepte mit unterschiedlichen Materialkombinationen. Zur Analyse und Auslegung der verschiedenen Konzepte wurden mehr als 500 FEM-Modelle erstellt und über 1.500 CAE-Simulationen durchgeführt.

Während sich Folgeprojekt 1 mit einer anwendungsbezogenen Testmethode und der Untersuchung der Sicherheit verschiedener Materialkombinationen für den Bodenaufprallschutz beschäftigt, steht in Folgeprojekt 2 die Flammresistenz verschiedener Materialien und Materialkombinationen im Vordergrund. Ziel ist es Prüfverfahren zu entwickeln, die es erlauben, die Aufprall-/Feuerbeständigkeit auf Materialebene unter Berücksichtigung der spezifischen Anforderungen an ein Batteriegehäuse im Vergleich zu Standardmaterialien zu untersuchen.

Firmen mit Interesse an Herstellung von Batteriegehäusen können sich an Philipp Fröhlig und Alexander Knauff wenden:
Philipp Fröhlig, AZL Aachen GmbH, Senior Project Manager, Tel: +49 241 47573514, philipp.froehlig@azl-aachen-gmbh.de
Alexander Knauff, AZL Aachen GmbH, Manager Industrial Services, Tel: +49 241 47573516, alexander.knauff@azl-aachen-gmbh.de

 

Source:

AZL Aachen GmbH

19.10.2021

Teijin to boost Heat-Resistant Carbon Fiber Prepreg Production

Teijin Limited announced today that its carbon fiber subsidiary Renegade Materials Corporation, a leading U.S.-based supplier of highly heat-resistant thermoset prepregs, resins and adhesives for the aerospace industry, will expand its prepreg production by 2.5 times approximately. The increased capacity, which aligns with Renegade’s capacity expansion strategy at the Miamisburg, Ohio location, is the result of a USD 4 million investment made in December 2019 and the construction was started in March 2020. Operation of the new production lines will commence January 2022.

Renegade Materials' heat-resistant thermoset prepregs, resins and adhesives are well trusted by U.S. and European aircraft manufacturers and aircraft engine suppliers.

Renegade Materials will showcase its high heat-resistant thermoset prepreg at the Composites and Advanced Materials Expo (CAMX), one of the largest, most comprehensive composites and advanced materials event in North America, at the Dallas Convention Center in Dallas, Texas, from October 19 to 21.

Teijin Limited announced today that its carbon fiber subsidiary Renegade Materials Corporation, a leading U.S.-based supplier of highly heat-resistant thermoset prepregs, resins and adhesives for the aerospace industry, will expand its prepreg production by 2.5 times approximately. The increased capacity, which aligns with Renegade’s capacity expansion strategy at the Miamisburg, Ohio location, is the result of a USD 4 million investment made in December 2019 and the construction was started in March 2020. Operation of the new production lines will commence January 2022.

Renegade Materials' heat-resistant thermoset prepregs, resins and adhesives are well trusted by U.S. and European aircraft manufacturers and aircraft engine suppliers.

Renegade Materials will showcase its high heat-resistant thermoset prepreg at the Composites and Advanced Materials Expo (CAMX), one of the largest, most comprehensive composites and advanced materials event in North America, at the Dallas Convention Center in Dallas, Texas, from October 19 to 21.

Source:

Teijin Carbon Europe GmbH

(c) Teijin Limited
13.07.2021

Teijin: Carbon Fiber Products Operations in Vietnam

TCV, Teijin’s carbon fiber business base in Vietnam, was established in May 2019. Teijin Limited announced that Teijin Carbon Vietnam Co., Ltd. (TCV) in Ha Nam, Vietnam, has started operating commercially to manufacture carbon fiber products including prepreg, a fiber sheet pre-impregnated with matrix resin as an intermediate material for composites. TCV initially will produce carbon fiber materials for sports and outdoor activities, including fishing, golf, bicycle and ice hockey goods, for markets in Southeast and South Asia and Asia-Pacific. Sales will be handled by TCV as well as carbon fiber sales affiliates of Teijin operating in these markets.

Teijin’s sales affiliates in Singapore, Shanghai and Taipei work to identify demand opportunities as well as provide customer services in Asia. Internal collaborations between these companies and TCV shall strengthen Teijin’s presence in the upstream and downstream sectors of Asia’s fast-growing markets.

TCV, Teijin’s carbon fiber business base in Vietnam, was established in May 2019. Teijin Limited announced that Teijin Carbon Vietnam Co., Ltd. (TCV) in Ha Nam, Vietnam, has started operating commercially to manufacture carbon fiber products including prepreg, a fiber sheet pre-impregnated with matrix resin as an intermediate material for composites. TCV initially will produce carbon fiber materials for sports and outdoor activities, including fishing, golf, bicycle and ice hockey goods, for markets in Southeast and South Asia and Asia-Pacific. Sales will be handled by TCV as well as carbon fiber sales affiliates of Teijin operating in these markets.

Teijin’s sales affiliates in Singapore, Shanghai and Taipei work to identify demand opportunities as well as provide customer services in Asia. Internal collaborations between these companies and TCV shall strengthen Teijin’s presence in the upstream and downstream sectors of Asia’s fast-growing markets.

Increasingly strict environmental measures and the upgrading of environmental frameworks, such as sustainable development goals (SDGs) and the Paris Agreement, are expected to stimulate greater use of lightweight and highly rigid carbon fiber. Demands are growing in Asia, especially in the fields of sports and outdoor activities, industry and aerospace. COVID-19, for example, has led to new trends in sports and outdoor activities, such as renewed interest in fishing due its compatibility with social-distancing protocols.

Source:

Teijin Limited

02.06.2021

Teijin: Tenax™ Carbon Fiber Prepreg Adopted for Next-Generation Aircraft Engine Nacelle

Teijin Limited announced today that its Tenax™ carbon fiber prepreg has been adopted for a part of nacelle, or streamlined housing, for next-generation aircraft engine to be used by Airbus. A prototype of the nacelle part, which Nikkiso Co., Ltd. is developing for Airbus’s Propulsion of Tomorrow project, will be delivered to Airbus by the end of 2021.

The Tenax™ prepreg used for the nacelle part was developed especially for aircraft applications using high-performance and rapid-curing epoxy resin. Notably, the Tenax™ prepreg can be molded at a lower temperature and in a shorter time than conventional prepregs for aircraft applications. In addition to general autoclave molding, the Tenax™ prepreg also is suited to press molding for mass production, achieving excellent quality required for aircraft applications. Furthermore, it is compatible with automated fiber placement (AFP) therefore can be combined with automatic laminating technology and short-time molding to maximize production efficiency. The excellent productivity and cost efficiency of the Tenax™ prepreg were key reasons why it was adopted for Nikkiso’s nacelle.

Teijin Limited announced today that its Tenax™ carbon fiber prepreg has been adopted for a part of nacelle, or streamlined housing, for next-generation aircraft engine to be used by Airbus. A prototype of the nacelle part, which Nikkiso Co., Ltd. is developing for Airbus’s Propulsion of Tomorrow project, will be delivered to Airbus by the end of 2021.

The Tenax™ prepreg used for the nacelle part was developed especially for aircraft applications using high-performance and rapid-curing epoxy resin. Notably, the Tenax™ prepreg can be molded at a lower temperature and in a shorter time than conventional prepregs for aircraft applications. In addition to general autoclave molding, the Tenax™ prepreg also is suited to press molding for mass production, achieving excellent quality required for aircraft applications. Furthermore, it is compatible with automated fiber placement (AFP) therefore can be combined with automatic laminating technology and short-time molding to maximize production efficiency. The excellent productivity and cost efficiency of the Tenax™ prepreg were key reasons why it was adopted for Nikkiso’s nacelle.

Teijin is intensively accelerating its development of mid- to downstream applications for aircraft, one of the strategic focuses of its medium-term management plan for 2020-2022. Going forward, Teijin intends to further strengthen its carbon fiber and intermediate material businesses to contribute to increasing global sustainability, aiming to become a company that supports the society of the future.

Source:

Teijin