Eco-friendly and resource-saving trends, as well as increased mobility, are driving the development of alternative drive technologies such as electromobility. Electric vehicles rely on powerful lithium-ion batteries. It will be a powertrain component, but it should also enable new forms of connectivity and autonomy.
Covestro has created numerous flame retardant polycarbonate mixes for encapsulating lithium-ion batteries for laptops and other electronic devices. The materials can also be used to make modules, housing parts, cell holders, and crash absorbers for electric car batteries. They are lightweight, strong, dimensionally stable, and can be flame retardant depending on the application.
The company will exhibit its latest thermoplastic breakthroughs, as well as battery components made from polyurethane and pultruded efficiently at the Battery Show in Stuttgart.
According to Dr. Julian Marschweski, Covestro's expert in electromobility, "our current focus is on developing procedures for effective mass manufacture of complex plastic parts for batteries." For the battery's interior, our fireproof plastic sheet blends must be manufactured into thin-walled pieces.
Covestro and Henkel are currently working together to permanently connect plastic parts in high-voltage batteries using UV-activated Loctite adhesives. Test parts built of flame-retardant PC+ABS blend Bayblend FR3040 EV are being used by the partners. With a one-millimeter thickness, the plastic already meets the UL94 category V-0 flammability rating but has good UV permeability above 380 nanometers.
Circular battery cells could be permanently bonded to the cell holder. Loctite adhesives are single-component systems that cure under UV light in under 15 seconds. As a result, the combination of UV-permeable plastic and fast-curing glue enables mass manufacture of battery modules and battery packs.
Lithium-ion batteries must be impact-safe. Covestro has developed a whole concept with several materials to cover battery units in such a container. The bottom of the battery container is stabilized by profiles made of continuous glass fibers or carbon fibers and a Baydur PUL polyurethane matrix pultruded.
According to industry standard side-impact protection testing, the profiles are strongest in the longitudinal direction. At the same time, components may be easily integrated with other materials and made efficiently.