Saudi Arabia basic Industries Co., Ltd. (, Sabic)) has developed a concept of (EV) battery pack for plastic-intensive electric vehicles using a systems engineering approach, highlighting the ability of lightweight plastics to meet the needs of key industries such as flexible design and performance. Compared with traditional battery pack designs using aluminum and other metals, Shaki Industries's concept uses lightweight thermoplastics, which can reduce the weight of each battery module by 30% to 50%, increase the energy density of battery modules, and simplify the battery assembly industry. reduce costs, improve thermal control and safety, and improve crashworthiness.
"our research on automotive electrification technology is not only about matching materials with individual battery components in existing designs, our expert team has taken into account the entire electric vehicle battery system and vehicle structure, so we are well able to help automotive customers achieve the most critical automotive research and development goals," said Abdullah Al-Otaibi, general manager of ETP & Market Solutions at Shaki Industries.
The battery pack concept developed by Shaki Industries uses the properties and strength of thermoplastics to improve performance, reduce cost and weight, and support mass production. The highlights of the battery pack concept are:
1. A single cell is integrated into the battery package and placed in a thin-walled shell with 30% glass fiber filler and flame retardant (FR) Sabic ®polypropylene xi (PP) compound.
2. The geometric structures such as double-wall structure, novel pattern and innovative integrated function are reinforced by sand-based industrial thermoplastics to reduce weight and meet structural requirements.
3. creatively adopt the anisotropic thermal conductivity of plastics to optimize the thermal management performance;
4. The battery tray integrates the plastic-metal mixed structure and STAMAX FR long glass fiber PP material to optimize the heat conduction, meet the requirements of the drop test, and absorb the huge impact force borne by the side frame structure.
5. The battery package shell is molded with STAMAX FR resin, and this material meets the flammability grade of UL94 Vmur0, and can be made into a metal shell to shield electromagnetic interference ((EMI)) and radio frequency interference ((RFI);).
6. Thermoplastic materials have the characteristics of degree of freedom in design, which can reduce the number of parts, improve assembly efficiency, and finally save battery manufacturing cost.
Through continued cooperation with the automotive industry, Shaki expects to launch several large battery casings molded with its thermoplastic materials for mass production of electric vehicles as early as 2024. At present, (PHEV), a plug-in hybrid electric vehicle in China, is using Shaji Industry's PP compound instead of aluminum to make battery case, thus achieving weight reduction, increased design freedom, warping control and other advantages.
At present, electric vehicles produced around the world are also using materials from Shaji Industry to make battery components, such as cell carriers and housings, battery modules and battery housings.
