Sometimes You Really Can Get More With Less
Electric vehicles have captured the world’s imagination. At Trinseo, they’ve captured our imagination as well. To us, the same principles of innovation, science, engineering, and design that define the external aesthetics of an electric vehicle, also apply to the internal components. We’ve been hard at work reimagining how to house the most critical and expensive component of an EV, the battery, while also enhancing performance, protection, productivity, and profitability. The key, an innovative use of the proven D-LFT process, a technology where thermoplastic resin is directly compounded with glass fibers for enhanced mechanical properties, and then compression molded into a custom part shape. The benefits of the D-LFT process include short cycle times that are ideal for high volume manufacturing, part toughness due to the integration of long reinforcing fibers, along with structural flexibility and design freedom for complex part geometries using thermoplastics.
Moving away from heavy metal casings to high performance trays and covers made from thermoplastics, changes the game for EV OEM’s without compromising performance or protection. Using high performance thermoplastic means increased design flexibility for innovative functional integration that can add value, and production efficiency across a number of areas.
To learn more, watch our video below. And if you would like to talk about how we may be able to help you reach your lightweighting, performance and recycling goals, contact us.
Lightweight Plastic Solution For EV Battery Cell Pack Enclosure
With our deep knowledge on design and processing capabilities, Trinseo has introduced a halogen & PFAS free flame-retardant PC grade for the LFT-D process. The thermoplastic composite solution is:
- PC LFT-D
- Halogen & PFAS Free
- Flame Retardant
Transformation Process
LFT-D (Long-Fiber Reinforced Thermoplastic-Direct) is a manufacturing process used to produce fiber-reinforced thermoplastic composite materials with high efficient production steps:
- Direct Fiber Reinforcement: Continuous rovings or fibers are fed directly into the polymer melt without the need for semi-finished products.
- Compounding: The polymer and fibers are compounded together to form a mixture.
- Compression Molding: The mixture is then placed into a mold and subjected to heat and pressure to form the final composite part.
Benefits
- Option to replace heavier/more expensive rigid metal casings without compromising performance or protection. The Trinseo solutions offers electric insulation, heat insulation and the fire resistance the industry demands
- Shorter cycle times for high volume manufacturing
- Structural flexibility and greater design freedom for complex part geometries versus metal
- Can contain recycled PC content produced through our in-house PC dissolution technology
PC LFT-D Versus Main Competitors
While steel and other metal alloys are traditionally the benchmark for plastics in the context of metal replacement, they are also either heavier or have a bigger CO2 footprint. Alternatives, such as the up-and- coming SMC (sheet moulding compound, a glass-fiber reinforced polyester) or HP-RTM, are either non- recyclable or too costly. Trinseo’s solution can have an even lower CO2 footprint by using PC recycled through the company’s dissolution technology, including:
- > 25% weight reduction compared with steel top cover
- Lower cost vs HP-RTM (High-Pressure Resin Transfer Molding Technology)
- Approximately 30% lower carbon footprint vs aluminum
Trinseo's solutions are also compliant with the UL2596 standard thermal runaway test (3mm PC LFT-D +1mm Mica sheet) and bonfire testing (as defined by Chinese regulation GB38031).
Portfolio of Recycled Containing Solutions
A broad portfolio of PC and PC/ABS grades with various amounts of recycled PC exists for multiple applications for EVs. Target applications include cylindrical cell holders, pouch cell frames, module covers, end plates, and wire harness isolation plates.
Resources
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From design to manufacturing, we’ll work hand in hand with you to deliver customized sustainable solutions unique to the needs of your company and customers.
