A new project funded by the Valencian Regional Government and implemented by the Spanish Technological Institute for Plastics AIMPLAS will focus on assessing the potential to replace the metal casings of electric car batteries with casings made from thermoplastic composites. Called Veteria21, the project will develop and optimise these materials in order to create lighter-weight batteries that are more easily recyclable.
According to UNEP, the UN environment programme, the mobility and transport sector is the fastest-growing greenhouse gas emitting sector. It is expected to contribute over 30% of total GHG emissions in the future. Prodded by legislation and in response to market demand, this industry has now started to make the shift towards electric mobility, which relies on the use of batteries. Transitioning to an electrified automotive powertrain is a critical component of any emissions reduction solution.
Thermoplastic composites have become a trend in vehicle weight reduction for several reasons other than their reduced weight: mechanical resistance, adaptability to different manufacturing processes, short manufacturing cycles, ability to be combined with other materials, weldability, easy recyclability and adaptability to the circular economy.
Currently made of stainless steel and aluminium, li-ion battery modules are big and heavy: they account for from 20% to 30% of vehicle weight. As well, the number of manufacturing and assembly steps makes them cost-intensive to produce. The use of plastics makes it possible to integrate parts and functions, such as fasteners and thermal management components, simplifying assembly, reducing weight and cost.
“In general, 73% of vehicle weight corresponds to the metal components. Thermoset composites are therefore a lightweight alternative for battery casings. However, their recyclability and production rate work against them,” explained Begoña Galindo, AIMPLAS Sustainable and Future Mobility Group Leader. “For this reason, thermoplastic composites represent a good alternative.”