JEC COMPOSITES MAGAZINE - Issue #73 - June 2012 - 17

electric vehicle

A new type of battery pack module carrier
moplastics – Direct Compounding) technology was adopted in order to manufacture the part cost-effectively. The material consisted of carbon fibre supplied by Toray Industries and PA 6 provided by Kolon Plastics. The manufacturing process combines extrusion compounding and compression moulding technologies and is highly cost-effective for mass production in the automotive industry. was greatly reduced, from 35 (steel) to 3 (composite), which lowers the overall processing cost. X-ray inspection of the part by KATECH (Korea) showed no significant voids or defects. Belgian road simulating vibration tests (6000 km) and impact simulating sled tests (for 30G inertia loading) were carried out by Hyundai for durability and crashworthiness, respectively.

LG Hausys, together with its partners Hyundai Motor and Shinhan Mold, won a JEC Innovation Award in the Special Prize Category at the JEC Show Europe 2012 in Paris last March. The three Korean companies were rewarded for an all-composite battery pack module (BPM) carrier developed for an electric vehicle. What does their innovation consist in?
on mechanical performance validation, LG Hausys developed composite solutions for lightweight automobiles and conducts material, manufacturing, assembly and performance evaluations, and with Shinhan Mold for the development of advanced tooling for largesize automotive parts.

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G Hausys wanted to develop a part by establishing composite materials and manufacturing processes in a mass production scenario. The company’s R&D centre used computer-assisted engineering (CAE) to review and evaluate the composite part design, with the support of the business development and manufacturing departments for cost reduction and technical transfer issues.  For this project, with support of Hyundai Motor

The resulting innovation
The partners developed a process to manufacture a 100%-carbon composite structure for an electric vehicle battery module pack without steel reinforcement. LFT-D (Long Fibre TherStep by step manufacturing process

The material’s excellent recyclability meets the End of Life Vehicle (ELV) regulations, especially for thermoplastic components.

100%-carbon composite for mass production in the automotive industry Compared to steel: - Considerable weight reduction: single charge of the electric vehicle 31% (from 35 to 24 kg) - Cost reduction by direct - Function integration, part compounding (no intermediate count reduced by 91% (from 35 products) to 3 per vehicle) - Enhanced driving performance - No need for anti-corrosion due to the weight reduction painting - Superior recyclability (thermo- Higher driving distance per plastics)

More information

Future of this technology
The development phase before mass production of electric vehicles is in progress (target launch date: 2014). The composite BPM carrier is 31% lighter than an equivalent steel version. The number of sub-parts No73 June 2012

No damage or cracks were reported in the composite part. The potential market includes various structural automotive composite parts (spare wheel well, seat structure, bumper beam, engine mount, frontend module carrier and oil pan), as well as Zero-Emission Vehicles (ZEV) due to the weight and cost reductions achieved. n
More information: www.lghausys.com http://worldwide.hyundai.com http://shinhanmold.co.kr

/ jec composites magazine 17
http://www.lghausys.com http://worldwide.hyundai.com http://shinhanmold.co.kr
JEC COMPOSITES MAGAZINE - Issue #73 - June 2012

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #73 - June 2012
