Mitsubishi Chemical Elevates Electric Vehicle Lightweighting at Battery Show

Mitsubishi Chemical is proudly showcasing its latest groundbreaking innovation at booth 711 in The Battery Show North America, held in Novi, MI. This event, organized by Informa Markets – Engineering, the parent company of PlasticsToday, is set to conclude on September 14.

At the core of Mitsubishi Chemical's presence lies its pioneering electric vehicle (EV) battery enclosure, crafted entirely from composites. This collaborative endeavor combines Mitsubishi Chemical's extensive portfolio of fiber-reinforced composite materials for advanced energy storage systems, EDAG's proficiency in mobility engineering, and Kreisel Electric's specialized expertise in the design and manufacture of battery storage systems.

This cutting-edge design effectively addresses a range of challenges associated with traditional EV battery enclosures. Typically, these enclosures are constructed using heavy metallic profiles, which can adversely impact the overall weight and performance of the vehicle. The transition to composite materials not only meets the requirements for EV battery housing but also substantially reduces weight.

John Conn, who serves as the engineering project manager at Mitsubishi Chemical Group, conveyed his excitement and noted that it represented an exciting breakthrough with the potential to significantly impact the rapidly expanding electric vehicle market. He further emphasized that, aside from its remarkable lightweight nature, the functional composite structure delivered robust performance, ensured high safety standards, and exhibited exceptional durability.

Another noteworthy aspect of the composite enclosure is its part consolidation strategy. The system boasts just two components, a significant departure from the initial EDAG design, which featured a metal housing comprising five separate parts. This simplification of downstream processes not only reduces costs but also enhances sustainability. Some components are recyclable and incorporate recycled content, elevating the product's circular economy credentials.

Within the battery enclosure, various Mitsubishi Chemical composite materials are employed. This includes a flame-retardant fiber-reinforced thermoplastic material for the top cover, capable of withstanding high-intensity thermal runaway events. Additionally, an extra layer of insulative material, made from Mitsubishi Chemical's Maftec polycrystalline alumina fibers, further bolsters the battery cover's protective properties.

The bottom tray of the enclosure was developed using two distinct materials: prepreg sandwich and carbon-fiber forged molding compound (CF FMC). It was produced through an innovative single-process step to meet thermal, geometric, and structural requirements. Moreover, Mitsubishi Chemical handled the fabrication of its tooling in-house and oversaw the assembly process, highlighting an agile and vertically integrated value chain capable of meeting OEM demands for tailored solutions.

Engineered by EDAG, a renowned engineering services provider, this lightweight enclosure has been developed in collaboration with battery system manufacturer Kreisel Electric. The latter leveraged its patented immersion cooling technology to create this innovative solution.