Best practice: Development of a technology demonstrator from LCP-LGF Development of components for use in battery housings for electric vehicles
© IKVAs part of a bilateral development project between Sumitomo Chemical Europe S.A./N.V. and the Institute of Plastics Processing (IKV), a demonstrator geometry of a battery housing cover for electric vehicles was developed. The new development of a long glass fiber reinforced liquid crystalline polyester (LCP-LGF) by Sumitomo Chemical Europe opens up new application possibilities for LCP. The inherent flame retardancy without additional flame retardants as well as the excellent flow and processing properties enable use in complex, large-volume components with high thermal, mechanical and flame retardancy requirements.
The aim of the collaboration was to demonstrate the advantageous properties of the material using a practical component from the field of electromobility.
Use case scenarios for material substitution in the battery housing
To demonstrate the property profile of the new material, IKV developed use case scenarios for the use of LCP-LGF in battery housings for passenger cars in collaboration with Sumitomo Chemical Europe. First, the individual components of a battery housing were analyzed with regard to their functions, requirements and regulatory specifications. Subsequently, the material substitution by LCP-LGF was investigated and the material was compared with competing materials.
Development of a demonstrator with functional integration
A central task was to develop a component that covers a broad property profile by means of functional integration and at the same time meets the high cost pressure for plastic components. The choice fell on a battery housing cover with a high level of functional integration. The component meets high requirements for flame retardancy and rigidity and, due to its size, requires good processing properties and high molding accuracy. Additional functional elements such as coolant supply lines and electrical lines should be integrated into the component.
Further developments and geometric designs
As part of a follow-up project, corresponding demonstrator geometries were developed and methods for dimensioning for the mechanical design were investigated. The development was based on VDI 2221 for the development of technical products in the task clarification, conceptualization and design phases.
Three final geometries were created:
- The full-size battery housing cover with various functional elements.
- A cell contacting system that combines electrical connection elements and facilitates assembly.
- A scaled functional demonstrator that combines the functional elements of the individual components and demonstrates the material properties of the LCP-LGF in a practical way. The handy function demonstrator is suitable for company visits and customer tests.
Validation and method development for the simulation of component properties
The development of methods for the numerical prediction of component properties and their validation was carried out on test specimens made of LCP-LGF produced at IKV. The samples were analyzed at the Center for Plastics Analysis and Testing (KAP). The fiber orientation distribution was recorded using μCT scans and the deformation behavior was mechanically tested. On this basis, finite element models were created and a calibration routine for micromechanical models was developed.
At the same time, the injection moulding simulation was validated and the prediction of the fiber orientation distribution was optimized. The researchers identified a need for optimization in the modeling of the melting behavior of LCP-LGF and the orientation modeling. Due to the special viscosity behavior of LCP, more precise viscosity models are required.
Optimisation potential and simulation models
In the course of the method development, optimisation potentials for existing simulation models and for the development of the LCP-LGF were identified. In particular, dealing with the special viscosity behavior of liquid crystalline LCP required detailed consideration and adaptation of the viscosity models.
Conclusion and outlook
In the joint project, the goals of developing a technology demonstrator – in the form of a battery housing cover and comparable components – were successfully achieved. For the subsequent phase IV according to VDI 2221, the geometry elaboration to the component, simulative methods were developed to take into account the production-related local anisotropy due to the fiber orientation distribution.
In addition, optimization potentials for existing simulation models and development progress of the LCP-LGF were identified and discussed.
Hakan Çelik, M. Sc.
Head of the Department Structure Calculation and Materials Science
This project was initiated and sponsored by Sumitomo Chemical Co. Ltd. and carried out in cooperation with Sumitomo Chemical Europe S.A./N.V.
High-Performance Engineering Plastics Department
Advanced Materials Division
Sumitomo Chemical Co., Ltd.
Phone: +81-3-5201-0266
Website
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