Thermoplastic Solutions for Battery Packs

摘要

SABIC is pursuing two approaches in developing thermoplastic solutions for battery pack designs. 1) Material solutions to increase gravimetric (W?h/Kg) output The primary focus of material research at SABIC is the development of low-density thermoplastic materials within our product families that target battery pack requirements, in particular: . UL94 V0 flammability rating at minimum thickness (0.7-1.5 mm) . Chemical resistance testing to coolants and electrolytes . Adhesive compatibility for ease of integration . High specific strength and stiffness for outer housings 2) Design solutions to increase volumetric (W?h/L) output and safety Application development for battery packs targets an increased ease of battery stacking in their modules, improved cooling and the integration of safety features to absorb crash energy and mitigate runaway cell reactions. The overall effect is a reduction in pack volume and assembly time. This poster presents an overview of these two development areas. Material solutions are highlighted by showing the components of the battery pack with their critical requirements (CTQs) and the thermoplastic materials that best fit those requirements. Two heat maps for components - a cylindrical cell carrier and an upper pack cover - allow an understanding of the primary performance requirements and the fit of the proposed thermoplastic materials. The objective is to enable the substitution of aluminum, while maintaining safety and thermal performance. The end goal is an increase in gravimetric performance (W?h/Kg) of the pack, achieved by minimizing the area weight of the individual components while respecting their CTQs. The second development area involves designing compact solutions based on the selected thermoplastics. This is achieved by integration of components (e.g. side pole impact protection, undertray impact and fire protection) based on hybrid plastic-metal solutions and improved thermal control pathways. SABIC validated improvements of 15 percent in volumetric output and 10 percent in gravimetric output when applying these proposed solutions for the battery pack of a specific commercial vehicle.