When combined with compression molding, D-LFT allows the molder to readily modify the glass content (if needed) and also allows the freedom to change glass type or change to carbon fiber. It is suitable for geometries with significant changes in wall thickness.
Compression molding also enables the optional combination of D-LFT with Tepex composite sheets, a solution for structural enhancements and improved protection from thermal runaway.
The realized advantages of thermoplastic battery enclosures include:
- Single compression molding step
- Part and function integration
- Significantly reduced assembly steps
- Overall reduced costs
- High recyclability potential with lower carbon footprint
- Weight savings over the aluminum design
“The single-piece design provides better dimensional tolerances than multi-piece trays, and the simple construction requires less production space,” Kauffmann said. “A reduced number of suppliers means less logistics and more material consistency.”
In addition, it delivers on the EV industry’s stringent fire resistance tests and electromagnetic shielding (EMS) requirements by adding mica sheet and aluminum foil.
We believe that smarter use of materials and more advanced materials will lead to further parts consolidation for applications like the battery enclosure,” Kauffmann said. “For example, although mica sheet was needed for thermal runaway protection, we believe that Tepex offers potential for thermal runaway protection that can be incorporated into the battery enclosure top cover.”
As a solutions provider, Envalior offers numerous solutions for both compression molding and injection molding with in-house engineering knowhow to support design and engineering.
Kauffmann concluded, “We are seeing more pull from the marketplace for plastic battery enclosures to address cost and weight. Although compression molding was selected for this battery enclosure prototype, injection molding technology exists for molding these very large parts. The main benefits of injection molding are greater functional integration and process repeatability. Envalior offers a wide range of materials and engineering solutions to help our customers meet their performance and cost targets for battery enclosures.”
