batteriewanne aus bio-kunststoffen dr. martin skrikerud · with a co2 neutral product lifecycle ....

Scandinavian Scalable Advanced Composites™

Batteriewanne aus Bio-Kunststoffen

Dr. Martin Skrikerud

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Edison did not invent the lightbulb through continuous improvement of the candle

By 4028mdk09 - Own work, CC BY-SA 3.0,

https://commons.wikimedia.org/w/index.php?curid=8361003

Thomas Edison

Menlo Park 1879

X


Can continuous improvement of steel lead to lighter steel?

X


We need: a disruptive change for a lighter solutions and a sustainable future

Steel monocoque with Duroplast body = 600 kg

Built in East Germany 1957-1991


Scandinavian Scalable Advanced Composites

About SSAC

Newly started company in Sweden with highly skilled and motivated people, focusing

on enabling cost efficient and scalable manufacturing of advanced composite parts

We combine expertise in composite engineering, materials and processes as well as

experience in high volume manufacturing of complex sheet metal forming in several

sectors



Vision

Driving the transition to sustainable lightweight vehicles with a CO2 neutral product lifecycle



Sample: Battery box concept From Tesla’s 34 parts to SSAC’s 2 parts

In cooperation with Kreisel Electric, Austria



Tesla's current design

Contains 7104 Li-ion batteries at 18 mm width and 65 mm height, adding up to a total size of

2681x1563x150 mm. Total battery weight app 500 kg (depending on version), the aluminium frame

weight is app. 130 kg, 34 parts - a combination of blanks, extruded profiles and cast aluminium.



Battery concept with 75 kWh Box produced in TAC

Battery case consists of only 2 parts, one

upper and one lower

Upper and lower part are pressed in one

shot

75 kWh of batteries for up to 500 km range

Batteries mounted on the flanges of the

battery housing, no direct contact to top or

bottom (4mm gap in the bottom, 2 mm in

the top)

Batteries provided by Kreisel



Battery housing – requirement 200 kN, Ø 150 mm cylinder from the side

Deformation 1.8 mm

Minimal Deformation of box

Flange will collapse, box will get some cracks, but not collapse

Flange designed to take the load



1 2 3

4

6

5

200 kN load cases for simulation (Ø 150 mm)



Battery housing – requirements fulfilled

All crash/crush requirements – ok

Tightness (water, dust etc.) – ok

Corrosion – ok

Electromagnetic shielding – ok

Fire protection – ok

Electrical insulation – ok

Cooling / heating – ok

Climate requirements – ok



Weight and cost comparison

Weight:

Aluminium: 130 kg

TAC composites 58 kg

TAC is 72 kg lighter than aluminium!

Cost comparison What is the cost per kg saved?

3.5 € / kg Based on carbon fibres available today

0 € / kg Based on future bio-based carbon fibres

As a reference, in RTM: 30 € / kg

Assumption: high volume manufacturing, > 100’000 vehicles / annum



Our solution Tailored Advanced Composites



A new way of processing and building composites parts – TAC

Tailored Advanced Composites is a new way of processing and building

composites parts:

Based on A-SMC, which is based on SMC – Sheet Moulding Compound – originally

developed for glass fibre compounds

Based on carbon fibres – best performance / weight ratio, but possible to add other fibres

(e.g. aramid) for special requirements

We use chopped carbon fibres (app. 50 mm long) as base material, but add unidirectional

fibres where needed to fully tailor the part performance

As a matrix we use vinyl ester for best performance/price/weight ratio

Automated process for high efficiency, low cycle times, cost efficiency and repeatability



TAC sample explained

Base material: chopped carbon fibres

Add Kevlar mat for intrusion protection

Add fire protection to matrix

Add thicker flange for

pole crash test

Add unidirectional

fibres for extra

strength

Geometrical freedom to add flanges

Thinner material

for weight saving

Add fixture

points for

batteries

Electromagnetic shielding

All produced in one operation

Add fastening elements for easy assembly



How strong is the material? It is tailored to fit the need!

This is the new XC90 body

It is tailored to fit the need with many different strength

steels and aluminium sheet and castings.

The range is app. 200 – 1500 MPa UTS

Source: Volvo Cars

With TAC, we start with a base material strength of app 300

MPa UTS. Then we add unidirectional fibres, mats, Kevlar,

aluminium or steel parts, to adjust the strength as needed, up

to 2000 MPa.

The range is app. 200 – 2000 MPa UTS.

But: all tailoring is done in one single manufacturing step



Advantages of TAC

Similar to sheet metal forming

Using chopped fibres of app. 50 mm length enables a very efficient pressing of the material

Random fibres give a close to isotropic behaviour

Netshape forming reduces material waste and trimming operations

Possible to create stiffeners in the same operation

Possible to create tailored properties by:

Seamlessly varying thickness

Add patches of unidirectional fibres of various length

Local specific press force to create a flow of fibers in the mould orienting the fibres in the flow direction

Possible to add screws/bolts etc. for joining

Base material at lower cost compared to traditional composite forming like RTM

Can reduce number of parts by a factor 10-20 in complex structures, and further savings in following operations

Very complex parts can be manufactured which gives full design freedom

TAC enables to have material only where needed, which maximises lightweighting weight saving of up to 75% possible

TAC enables low cycle times and highly automated scalable production lines well suited for the automotive industry



Possible products in automotive

http://www.cenex-lcv.co.uk/2015/assets/downloads/presentations/nick-warrior.pdf



Why is weight saving so important?

Lighter battery box

Lighter chassis

Smaller engine

Smaller battery back

Today 1 kWh is 200-250 €.

If we can save battery and keep the same range, the cost saving can be huge.



Advantages of a composite design and possible weight saving

Composite design with carbon fibres

Density of app. 1.5 compared to 7.8 of steel of 2.7

of aluminium

High strength; 4 GPa compared to 0.3-1.5 GPa of

steel and 0.2-0.5 GPa of aluminium

High stiffness; 240 GPa compared to 210 GPa of

steel and 70 GPa of aluminium

Carbon fibres made from renewable sources (i.e.

wood) allows completely CO2 neutral

manufacturing.

(values for fibres, finished composite part will have

different properties depending on the part design)

Carbon fibres offer the best weight saving potential!

Source: Volkswagen



Material The future is bio-based



From CO2 emissions during use to life cycle requirements

Today the focus is on CO2 emissions in the use phase of the cars

In the future, the complete life cycle will be the important factor

Carbon fibres today, based on fossil oil, produced with “dirty” electricity is not a good solution

Carbon fibres produced from renewable plant base and renewable electricity offer a

completely CO2 neutral production alternative to steel or aluminium

Today the Carbon cycle is dominated by burning fossil carbon. We have to stop that,

and create a new carbon cycle, where we don’t burn the carbon, but use it as one of

the strongest building materials nature has given us.


Carbon fibres are today produced from fossil oil.

POLYAKRYLONITRIL fibres gets carbonised

Picture from the BMW production plant in Moses Lake, USA)


Sources for making carbon fibres

Crude oil

» What is crude oil made of?

Different constituents of plants

» Lignin from paper pulp is state of the art

» New approach to get lignin from saw dust

» Cellulose

99% OF ALL PLANTS ARE:

- CELLULOSE

- HEMICELLULOSE

- LIGNIN


CARBON FROM PLANTS

IS THIS AN ALTERNATIVE?

HAVE YOU EVER DONE A FIRE?

Yes, it is based on carbon. Can it be used

to make technical fibers?



Future bio-based composites

First composite laminate with

carbon fibres from lignin,

produced in Sweden in

September 2015


ROCKET

SCIENCE?



The heatshield to the USA

Space shuttles were made of

Carbonised Viscose fibres from

Sweden.

Viscose is a fibre made from

Cellulose, one of the three main

constituents of all plants!

YES, ROCKET SCIENCE!



Carbon cycle

From million of years to 100 years to close the carbon cycle



Conclusion

The proposed concept will enable a CO2 neutral, scalable

manufacturing of high performance lightweight parts that meet:

future requirements from the governments

the demands from the OEMs

the expectations from the future customers

Contact: [email protected]

batteriewanne aus bio-kunststoffen dr. martin skrikerud · with a co2 neutral product lifecycle ....

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