Current leaders: Covestro at the Battery Show Europe 2019

The core element of future mobility concepts is a powerful lithium-ion battery, which will be part of the powertrain but should also enable new forms of connectivity and autonomous driving. Covestro Due to their favourable property profile, polycarbonate blends are well suited for manufacturing modules, housing parts, cell holders and crash absorbers (as can be seen in this picture) for electric car batteries.

Covestro has many years of experience with covering lithium-ion batteries for electronic devices and has developed various polycarbonate blends for this purpose. Due to their favourable property profile, the materials are also suited for manufacturing modules, housing parts, cell holders and crash absorbers for electric car batteries. They are lightweight, robust and dimensionally stable, and can come equipped with a flame retardant.

At the Battery Show in Stuttgart, Germany, the company will present its current developments with thermoplastics and battery components that provide good impact protection and are efficiently manufactured from polyurethane using the pultrusion process. Efficient mass production

Dr Julian Marschweski, electromobility expert at Covestro, said: "A current focus of our activities is the development of processes for the efficient mass production of complex plastic parts for batteries. In order to accommodate as many cells as possible in the battery’s interior, our flame-retardant polycarbonate blends must be processed into especially thin-walled parts."

A current co-operation between Covestro and the adhesive manufacturer Henkel involves permanently bonding plastic parts in high-voltage batteries with UV-activated Loctite adhesives. The partners are testing this on injection-moulded parts made of the flame-retardant PC+ABS blend Bayblend FR3040 EV. The plastic already meets’ category V-0 of the Underwriters Laboratories’ UL94 flammability rating.

The Loctite adhesives are processed as a single-component system and harden under UV light in under 15 seconds. The combination of UV-permeable plastic and fast-curing adhesive enables the short cycle times required for the mass production of battery modules and packs. Maximum impact protection

Covestro has developed a complete concept with different materials, in order to provide battery modules with maximum protection. The bottom part obtains its stability from profiles, which are continually manufactured from continuous glass- or carbon-fibres and a duroplastic matrix from Baydur PUL using the pultrusion process.

The profiles are strongest in a longitudinal direction and keep battery modules safely in their shape, as documented in standard industry side-impact protection tests. At the same time, components can be manufactured efficiently and cost-effectively, and easily combined with other materials.

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