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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.

Battery Show 2022: Freudenberg presents liquid absorbers for lithium-ion battery packs (c) Freudenberg
Freudenberg battery pack liquid absorbers
18.05.2022

Freudenberg auf Battery Show 2022

  • Freudenberg presents liquid absorbers for lithium-ion battery packs

The experts from Freudenberg Performance Materials (Freudenberg) will be presenting battery pack liquid absorbers, an innovative solution that makes battery systems safer, at this year's Battery Show in Stuttgart. The absorbent pads capture and store unwanted liquids inside the packs quickly and reliably. With adjustable absorption capacity and geometries, battery pack liquid absorbers ensure long-lasting battery packs. Visitors will find Freudenberg at Stand C 36 in Hall 10 from June 28 to 30.

Battery packs are the core elements of mobile and stationary lithium-ion energy storage systems. They are used in automotive and industrial applications. The performance and lifespan of these components are largely responsible for the efficiency of the energy storage system. Moisture inside the packs, such as condensation water or leaking coolant, can considerably diminish both function and lifespan. Battery pack liquid absorbers act as a safety system: the special fleece quickly takes up condensate or coolant and stores it effectively.

  • Freudenberg presents liquid absorbers for lithium-ion battery packs

The experts from Freudenberg Performance Materials (Freudenberg) will be presenting battery pack liquid absorbers, an innovative solution that makes battery systems safer, at this year's Battery Show in Stuttgart. The absorbent pads capture and store unwanted liquids inside the packs quickly and reliably. With adjustable absorption capacity and geometries, battery pack liquid absorbers ensure long-lasting battery packs. Visitors will find Freudenberg at Stand C 36 in Hall 10 from June 28 to 30.

Battery packs are the core elements of mobile and stationary lithium-ion energy storage systems. They are used in automotive and industrial applications. The performance and lifespan of these components are largely responsible for the efficiency of the energy storage system. Moisture inside the packs, such as condensation water or leaking coolant, can considerably diminish both function and lifespan. Battery pack liquid absorbers act as a safety system: the special fleece quickly takes up condensate or coolant and stores it effectively.

Source:

Freudenberg Performance Materials Holding SE & Co. KG