Electric vehicle (EV) range anxiety is a major hurdle to acceptance. Increased power can be achieved by adding more modules to the battery but this can cause "mass compounding" that is, the additional power is partly offset by the added weight creating a diminishing return. If the batteries themselves can be lighter, this effect is mitigated, allowing a larger benefit from the additional batteries. EV battery applications seek lighter weight, lower cost materials for both liquid cooled and air cooled battery module housings. Experience has shown that flame retardation is a beneficial property for thermoplastic materials used in battery packaging. Covestro is investing in development of materials, design and manufacturing techniques to enable lower cost, lighter weight solutions for battery outer packs. For example, thermally conductive, electrically insulating materials can enable module packages that support the cells as well as provide thermal management. Covestro materials paired with the Long Fiber Thermoplastic molding technology can provide solutions for outer packaging; make it possible to overcome many issues with current materials such as aluminum. The result is better performance and lower energy density. Covestro's portfolio contains several products that can meet the requirements for air cooled and liquid cooled module packaging. However, specialized knowledge is often necessary to optimize designs for thermoplastic materials. Covestro has spent a great deal of time developing the knowledge and expertise to assist customers with material selection and designs that meet their needs, allowing them to focus on their core business. This poster presents our areas of focus and some of the completed and ongoing developments. Combining customer expertise with Covestro engineering tools and materials it is possible to achieve the next level of module and pack design today.
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