AP&T: A new concept for battery housings aims to be lighter and provide enhanced safety

电池外壳的新概念旨在减轻重量并提供更高的安全性

Together with RISE Department Polymer, Fiber and Composite in Sweden and Fraunhofer IWU and FiberCheck in Germany, AP&T has developed a new type of battery housing for electric cars. By combining aluminum foam and carbon fiber based sheet molding compound (C-SMC) composite in one and the same component, they have succeeded in reducing its weight and increasing its collision safety. The manufacturing itself is done in a single forming step.

AP&T与瑞典的RISE聚合物、纤维和复合材料部门、德国的弗劳恩霍夫协会模具和成型技术研究所（Fraunhofer IWU）及FiberCheck合作，共同开发了一种新型电动汽车电池外壳。通过将铝泡沫和碳纤维基片状模复合材料（C-SMC）结合在同一部件中，成功地减轻了外壳重量，并提高了其碰撞安全性。整个制造过程仅需一步成型即可完成。

A demonstrator component was manufactured at RISE T&D facility. Photograph: RISE.

在RISE 测试与开发设备中制造了一个展示部件，照片来源：RISE

Adequately protecting the heart of the car – the battery pack – is a vital target for all electric car manufacturers. At the same time, efforts are always being made to reduce the weight. So, what’s the optimal solution?
充分保护汽车的核心部件——电池组，是所有电动汽车制造商的重要目标。同时，人们也在不断努力减轻其重量。那么，最佳解决方案是什么呢？

"Today, battery housings can be manufactured using steel, aluminum, SMC materials, or even a combination of multiple materials to meet requirements for cost, lightweight design, and safety," explains Dr. Michael Machhammer, Manager of Development for Forming Processes & Tooling at AP&T.
AP&T成形工艺与模具开发经理Michael Machhammer博士解释说：“如今，电池壳体可以采用钢、铝、SMC材料，甚至多种材料的组合来制造，以满足成本、轻量化设计和安全性的要求。”

The collaboration parties’ solution combines many of the features that car manufacturers demand. Compared to the sheet metal battery housing that was used as a reference, they have achieved an 18% weight reduction. Simulation results has also shown significantly improved collision safety. During side impacts, the side pole simulation results showed 75% less material deformation, and in the bollard test simulation (impact from below), there was an improvement of approximately 30%.
共同合作的解决方案结合了汽车制造商所需的众多功能。与作为参考的金属板电池外壳相比，这些方案实现了18%的重量减轻。模拟结果还显示，碰撞安全性得到了显著提升。在侧面碰撞中，侧柱模拟结果显示材料变形减少了75%，而在系柱试验碰撞模拟 (从下方撞击) 中，材料变形改进了约30%。

A demonstrator showing the developed design solution for battery housings using aluminum foam and SMC composite reduces weight and increases safety. Photograph: RISE.

演示者展示了使用铝泡沫和SMC复合材料开发的电池外壳设计解决方案，该方案既减轻了重量，又提高了安全性，照片来源：RISE

Cost-effective manufacturing
经济高效的制造

For a new design solution to be industrialized, it is vital that it can be produced in a rational and cost-effective process, and here too, the collaboration project has delivered. The entire component is manufactured in a single step. C-SMC material is applied onto the aluminum foam-composite material along with special embroidered sensors. To achieve high accuracy during forming, using a servohydraulic press and dedicated tool is recommended. The integrated sensors can measure temperature, humidity, and various other parameters within the battery pack that may affect the capacity and lifespan of the battery cells.
要想将新的设计方案实现工业化，关键在于能够以合理且成本效益高的工艺进行生产，而在这方面，合作项目也取得了成果。整个部件仅需一步即可完成制造。C-SMC材料与特殊的刺绣式传感器一起被应用于铝泡沫复合材料上。为了在成型过程中实现高精度，建议使用伺服液压机和专用模具。集成传感器可以测量电池组内的温度、湿度以及可能影响电池组容量和寿命的其他各种参数。

“Our results show how the next generation of optimized battery housings can be designed and manufactured. Now we look forward to bringing our solution to interested OEMs and Tier 1 suppliers,” says Dr. Machhammer.
“我们的研究结果表明了下一代优化的电池外壳能够如何被设计和制造。现在，我们期待能将我们的解决方案提供给感兴趣的主机厂 (OEM) 和一级供应商。”Machhammer博士说道。

Dr. Michael Machhammer, Manager of Development for Forming Processes & Tooling at AP&T.

AP&T成形工艺和模具开发经理Michael Machhammer博士

Who has done what in the project?
我们在这个项目中分别做了什么？

• AP&T designed and manufactured the tool, and the demonstrator component was manufactured by RISE using a servohydraulic press produced by AP&T.
  AP&T设计并制造了模具，而展示部件则由RISE使用AP&T伺服液压机所制造。
• RISE manufactured the demonstrator component at its test facility in Piteå, Sweden.
  RISE在其位于瑞典皮特奥 (Piteå) 的测试设备中制造了展示部件。
• Fraunhofer IWU designed and conducted simulations of the component.
  弗劳恩霍夫协会模具和成型技术研究所（Fraunhofer IWU）设计并进行了该部件的模拟测试。
• FiberCheck designed and manufactured the sensors, which were integrated in the C-SMC/aluminum foam hybrid structure during the one-shot compression molding conducted at RISE.
  FiberCheck设计并制造了传感器，这些传感器在RISE进行的一次性压缩成型过程中被集成到C-SMC/铝泡沫混合结构中。
• Vinnova, Sweden’s innovation agency, contributed funding.
  瑞典创新机构Vinnova提供了资金支持。