Mitsubishi Chemical Group (MCG) exhibited its newest innovation in the form of an electric vehicle battery all-composite enclosure.
The partnered collaboration features Mitsubishi Chemical Group (MCG) with a diverse fiber-reinforced composite material portfolio for advanced energy storage systems, EDAG contributing its key engineering services to the mobility sector, and Kreisel Electric, specialized in designing and manufacturing battery storage systems.
The latest design overcomes many of the concerns surrounding traditional electric vehicle (EV) battery enclosures. Typically, these are produced from heavy metallic profiles which can have a negative impact on overall weight and vehicle performance.
By switching to composite materials, this battery concept can meet the requirements for battery housings for electric vehicles, while at the same time, being significantly lighter in weight.
Another key feature is that the composite enclosure is a simpler system with just two parts, compared to the initial EDAG design based on a metal housing comprised of five parts. This demonstrates the ability of composites to consolidate parts resulting in simplified downstream processes and cost savings. In addition, some components are recyclable and can include the use of recycled content, making for a product with high circular economy credentials.
Various MCG composite materials were incorporated within the battery enclosure, including a flame-retardant fiber-reinforced thermoplastic material for the Top Cover that can withstand high-intensity thermal runaway events. The enclosure also incorporates an additional layer of insulative material (MAFTEC) produced from alumina fibers to further protect the battery cover. The Bottom Tray was developed using two different materials, Prepreg Sandwich and CF FMC (Forged Molding Compound), produced using an innovative single process step to meet thermal, geometric, and structural requirements. In addition, MCG fabricated its own tooling and produced the assembly in-house, demonstrating an agile, vertically integrated value chain that can be adjusted to meet OEM requirements to create bespoke solutions.
Designed by engineering service provider EDAG, the lightweight enclosure has been developed in collaboration with battery system manufacturer Kreisel Electric utilizing its patented immersion cooling technology.
Source: Mitsubishi Chemical Group
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