Teijin Automobile Interview: How can advanced composite materials help future mobility?

The rapid development of electric vehicles has driven the demand for lithium batteries and structural parts in the industrial chain
.
The biggest challenges automakers and OEMs face when developing new electric vehicles are vehicle range, battery safety and battery serviceability
.

In an interview with AdsaleCPRJ.
com recently, Jack Dunagan, general manager of Teijin Automotive Technology Co.
Composite materials can help electric vehicles meet these challenges
.

Provides excellent protection and weight reduction for battery housings

Lightweight composite EV battery boxes and complete enclosures can increase vehicle range and reduce tooling costs
.
They also provide excellent crash protection for the battery
.

Advanced composite materials have thermal runaway or self-extinguishing capabilities, reducing the need for additional wraps and improving the overall safety of the vehicle
.
They won't dent or corrode, providing better protection for the battery
.

Teijin Motor Corporation develops multi-material EV battery case

Jack Dunagan said that ISO, IEC (International Electrotechnical Commission) and others are developing international standards for lithium-ion battery safety.
These standards continue to evolve with the development of technology, and also set requirements for compliance with the standards based on regional differences
.

“The battery pack must be protected against short circuits and thermal runaway, and the battery case must pass a variety of tests including mechanical shock, drop, penetration, immersion, crush/bump and flame
,” explains Jack Dunagan
.

According to him, proprietary composites (custom chemistries) can be used to meet different flame and thermal runaway requirements, such as traditional highly filled polyester/vinyl esters, intumescent modified and phenolic resins
.
Additionally, the composition of the composite can be adjusted by using glass/carbon/blend/or other chopped, continuous fibers
.
Teijin Motors can also adjust material formulations to meet the most stringent VOC requirements
.

"By using Teijin Motor's battery housing multi-material formulations, we can ensure vehicle safety, reduce overall vehicle weight, and provide OEMs and consumers with battery cases that are easier to service than welded and bolted battery cases,
" added Jack Dunagan.
Road
.

Teijin Motors observes an increasing demand for composite materials for battery covers and casings in the market
.
The company also noted increased demand for composite luggage and pickup boxes for electric pickups in the U.
S.
market
.

Jack Dunagan expects a similar trend in the Chinese market as restrictions on the use of Chinese pickups are eased in major cities
.

Plaque after thermal runaway test of Teijin Motor's intumescent material

Enabling the development of autonomous driving

Autonomous driving is one of the key technologies for future mobility, and it also provides more application scenarios for composite materials
.

"For example, self-driving cars, especially those used for ride-sharing, will 'wear out' more easily than privately owned cars," says Jack Dunagan, "while composite materials are resistant to dents, bites and corrosion, with lightweight composites Self-driving cars with body panels will be more durable than cars made with metal body panels, which are more likely to rust or dent
.
”

He also noted that because composites are processed by molding rather than stamping, many autonomous driving features, including lidar (light detection and ranging) and cameras, can be molded directly into the body or roof panel, reducing the need for cars Assembly complexity
.

Teijin Motors also recently launched its latest research and development - the new Hexacore material
.
As mentioned, this innovative material is essentially a sandwich composite, using a lightweight honeycomb core overlaid with a natural, glass or carbon fiber "skin" and wetted with PUR resin
.

The key property of the material is the 3D shape with an ultra-high stiffness-to-weight ratio, which means high stiffness and low weight can be achieved
.
“Honeycomb inner panels with composite outer panels are 26 percent lighter than panels made from composite inner and outer panels,
” he explained
.

The company is currently experimenting with a Grade A finish, which can be made from thermoset or thermoplastic skins
.

Process cost reduction and efficiency increase

Jack Dunagan emphasized that today's composite materials utilize technologically advanced chemical formulations that offer many significant advantages for automotive applications, including cost and weight savings, compared to steel and aluminum
.

Depending on the volume, tooling costs for composites can be 50-70% lower than stamping steel or aluminum
.
A single piece made of composite material can replace an entire assembly of metal parts
.
Reducing complexity saves assembly time and reduces required maintenance
.

“Replacement or repair of damaged composite body panels is much less expensive, four times less expensive than metal parts
.
Most composite parts are bolted on, with aluminum or steel parts requiring timely and complex repairs or Replace
," added Jack Dunagan
.

In addition to a very high strength-to-weight ratio and high impact strength, composites can be designed for high strength in specific directions of the molecular structure, while metals have equal strength in all directions
.

Additionally, composites enable designs that most metals cannot, because they are able to flow through molds and into deep cavities, forming bends or other complex shapes
.

Processing and molding of battery casings

"Composite instead of metal" needs to increase user awareness

“Teijin Motors has decades of experience in composite materials
.
We can formulate materials that meet customer specifications for crash, flammability, low VOC, etc.
, and then design parts, assemblies or even entire assemblies that optimize those qualities,” Jack Dunagan Go on
.

A major bottleneck for the company is training OEM engineers why, when and how to use composites instead of metals
.

“Automobiles and auto parts are traditionally made of metal, and OEMs are very proficient in metal design and metal part stamping
.
Many also have their own stamping operation tools, which makes the decision to use composites more challenging,
” he explained.

.

On the other hand, the automotive industry is in an era of sustainable development, and Teijin Motors is also working hard to reduce its impact on the environment
.
The company is currently working on various research projects, including life cycle analysis and recycling processes
.