Electric vehicle (EV) is a decisive force for future mobility, and is on the fast track of development. Some of the biggest challenges for automakers and OEMs in developing new EVs are vehicle range, battery safety and battery serviceability.

From the perspective of a powerhouse of composite and multi-material technologies in the automotive industry, Teijin Automotive Technologies believes that these challenges can be coped with advanced composite materials which meet the emerging requirements.

Jack Dunagan, General Manager, Teijin Automotive Technologies China, talked more in an interview with Adsale Plastics Network.

Superior protection and reduced weight for battery casing

Lightweight composite EV battery cases and complete enclosures can increase vehicle range and reduce tooling costs. They also offer superior crash protection for the batteries.

Advanced composite materials contain thermal runaway or self-extinguishing capabilities, reducing the need for additional wraps and improving overall vehicle safety. They do not dent or corrode, providing better protection for a battery.

A multi-material EV battery enclosure developed by Teijin Automotive Technologies.

As Jack Dunagan pointed out, international standards on Li-ion battery safety are being developed by ISO, IEC (International Electrotechnical Commission) and others, which continue to evolve as the technology develops. The pass/fail requirements are also set and vary regionally.

“Battery pack must protect against short-circuiting and thermal runaway, and battery boxes must pass a variety of tests including: mechanical shock, drop, penetration, immersion, crush/crash, and flame,” he explained.

According to him, proprietary composite materials (customized chemistries) can be used to meet varying flame and thermal runaway requirements, such as traditional high-fill polyester/vinyl ester, intumescent-modified, and phenolic. 

Chemistries can also be adapted utilizing glass/carbon/blended/other fibers or chopped and/or continuous formats. Teijin Automotive Technologies can formulate to achieve the most stringent VOC requirements as well.

“By utilizing our multi-material approach to battery enclosures, we can ensure vehicle safety, reduce overall vehicle weight, and provide the OEM and consumer with a battery box that is more easily serviceable than a box that is welded and bolted together,” said Jack Dunagan.

Teijin Automotive Technologies is seeing the demand for composites in battery covers and enclosures continuing to increase. In the U.S, the company also notices an increased demand for composite frunks and pickup boxes in electric pickups.

As restrictions in large cities ease regarding the use of pickups in China, Jack Dunagan expects to see a similar trend in the country.

Plaques of Teijin Automotive Technologies’ intumescent material following a thermal runaway test.

Enable the development of autonomous driving

Autonomous driving is another crucial part in future mobility, in which composites can also contribute in a number of applications for autonomous vehicle (AV).

“For example, it is expected that AVs, especially those used for ride sharing situations, will undergo more ‘wear and tear’ than a privately owned vehicle,” said Jack Dunagan. “Because composites are resistant to dents, dings and corrosion, an AV with lightweight composite body panels will naturally be more durable than one made with metal body panels that will eventually rust or be all dented.”

He also remarked that as composites are molded as opposed to stamped, many AV features, including LiDAR (Light Detection and Ranging) and cameras, can be molded right into the body or roof panel. This feature will reduce assembly complexity.

Meanwhile, Jack Dunagan shared the latest development from Teijin Automotive Technologies - the new Hexacore material.

As told, the innovative material is essentially a sandwich composite using a lightweight honeycomb core, clad with natural, glass or carbon fiber “skins” that are wetted with PUR resin.

The key advanced attribute is 3D shapes with ultra-high stiffness-to-weight ratio which represents very high stiffness and very low weight. “Honeycomb inner panel with composite outer panel reduces weight by 26% over a panel made with both composite inner and outer panels,” he explained.

The company is currently running trials with a Class A finish that can be made with either thermoset or thermoplastic outer skin.

Offer advantages over conventional materials

Today’s composites are technologically advanced chemical formulations that offer a number of significant advantages for automotive applications over steel and aluminum, including both cost and weight savings, emphasized Jack Dunagan.

Depending on production volumes, tooling costs for composites can be as much as 50-70% less than those for stamping steel or aluminum. A single piece made of composite materials can replace an entire assembly of metal parts. Reduced complexity saves assembly time as well as cuts down needed maintenance.

“A damaged composite body panel is far less expensive to replace or repair, as much as four times less expensive than a metal part. Most composite parts are bolt on, rather than timely, complex repair or replacement process associated with an aluminum or steel part,” added Jack Dunagan.

In addition to very high strength-to-weight ratio and high impact strength, composites can be engineered and designed to be strong in a specific direction, while metals are equally strong in all directions.

Moreover, composites can achieve design cues that are impossible with most metals because they are able to flow over the molds and into deep pockets, curves and other complex shapes.

Molding of the battery enclosure.

Education the bottleneck in increasing use

“Teijin Automotive Technologies has decades of experience working with composites. We can formulate materials that meet customer specifications for crash, flammability, low VOC, etc., and then design a part, component or even an entire assembly that best optimizes these qualities,” continued Jack Dunagan.

The main bottleneck the company faces is educating OEM engineers about why, when and how to use composites in place of metals.

“Cars and car parts are traditionally made from metal, and OEMs are very well versed in designing with metal and stamping out metal parts. Many have their own stamping operations too, making the decision to use composites even more challenging,” he explained.

On the other hand, the automotive industry is in the era of sustainability, Teijin Automotive Technologies is also striving to reduce its environmental impact. The company is currently engaged in a variety of research projects, including life cycle analysis and recycling processes.

Electric vehicle (EV) is a decisive force for future mobility, and is on the fast track of development. Some of the biggest challenges for automakers and OEMs in developing new EVs are vehicle range, battery safety and battery serviceability.

From the perspective of a powerhouse of composite and multi-material technologies in the automotive industry, Teijin Automotive Technologies believes that these challenges can be coped with advanced composite materials which meet the emerging requirements.

Jack Dunagan, General Manager, Teijin Automotive Technologies China, talked more in an interview with Adsale Plastics Network.

Superior protection and reduced weight for battery casing

Lightweight composite EV battery cases and complete enclosures can increase vehicle range and reduce tooling costs. They also offer superior crash protection for the batteries.

Advanced composite materials contain thermal runaway or self-extinguishing capabilities, reducing the need for additional wraps and improving overall vehicle safety. They do not dent or corrode, providing better protection for a battery.

A multi-material EV battery enclosure developed by Teijin Automotive Technologies.

As Jack Dunagan pointed out, international standards on Li-ion battery safety are being developed by ISO, IEC (International Electrotechnical Commission) and others, which continue to evolve as the technology develops. The pass/fail requirements are also set and vary regionally.

“Battery pack must protect against short-circuiting and thermal runaway, and battery boxes must pass a variety of tests including: mechanical shock, drop, penetration, immersion, crush/crash, and flame,” he explained.

According to him, proprietary composite materials (customized chemistries) can be used to meet varying flame and thermal runaway requirements, such as traditional high-fill polyester/vinyl ester, intumescent-modified, and phenolic. 

Chemistries can also be adapted utilizing glass/carbon/blended/other fibers or chopped and/or continuous formats. Teijin Automotive Technologies can formulate to achieve the most stringent VOC requirements as well.

“By utilizing our multi-material approach to battery enclosures, we can ensure vehicle safety, reduce overall vehicle weight, and provide the OEM and consumer with a battery box that is more easily serviceable than a box that is welded and bolted together,” said Jack Dunagan.

Teijin Automotive Technologies is seeing the demand for composites in battery covers and enclosures continuing to increase. In the U.S, the company also notices an increased demand for composite frunks and pickup boxes in electric pickups.

As restrictions in large cities ease regarding the use of pickups in China, Jack Dunagan expects to see a similar trend in the country.

Plaques of Teijin Automotive Technologies’ intumescent material following a thermal runaway test.

Enable the development of autonomous driving

Autonomous driving is another crucial part in future mobility, in which composites can also contribute in a number of applications for autonomous vehicle (AV).

“For example, it is expected that AVs, especially those used for ride sharing situations, will undergo more ‘wear and tear’ than a privately owned vehicle,” said Jack Dunagan. “Because composites are resistant to dents, dings and corrosion, an AV with lightweight composite body panels will naturally be more durable than one made with metal body panels that will eventually rust or be all dented.”

He also remarked that as composites are molded as opposed to stamped, many AV features, including LiDAR (Light Detection and Ranging) and cameras, can be molded right into the body or roof panel. This feature will reduce assembly complexity.

Meanwhile, Jack Dunagan shared the latest development from Teijin Automotive Technologies - the new Hexacore material.

As told, the innovative material is essentially a sandwich composite using a lightweight honeycomb core, clad with natural, glass or carbon fiber “skins” that are wetted with PUR resin.

The key advanced attribute is 3D shapes with ultra-high stiffness-to-weight ratio which represents very high stiffness and very low weight. “Honeycomb inner panel with composite outer panel reduces weight by 26% over a panel made with both composite inner and outer panels,” he explained.

The company is currently running trials with a Class A finish that can be made with either thermoset or thermoplastic outer skin.

Offer advantages over conventional materials

Today’s composites are technologically advanced chemical formulations that offer a number of significant advantages for automotive applications over steel and aluminum, including both cost and weight savings, emphasized Jack Dunagan.

Depending on production volumes, tooling costs for composites can be as much as 50-70% less than those for stamping steel or aluminum. A single piece made of composite materials can replace an entire assembly of metal parts. Reduced complexity saves assembly time as well as cuts down needed maintenance.

“A damaged composite body panel is far less expensive to replace or repair, as much as four times less expensive than a metal part. Most composite parts are bolt on, rather than timely, complex repair or replacement process associated with an aluminum or steel part,” added Jack Dunagan.

In addition to very high strength-to-weight ratio and high impact strength, composites can be engineered and designed to be strong in a specific direction, while metals are equally strong in all directions.

Moreover, composites can achieve design cues that are impossible with most metals because they are able to flow over the molds and into deep pockets, curves and other complex shapes.

Molding of the battery enclosure.

Education the bottleneck in increasing use

“Teijin Automotive Technologies has decades of experience working with composites. We can formulate materials that meet customer specifications for crash, flammability, low VOC, etc., and then design a part, component or even an entire assembly that best optimizes these qualities,” continued Jack Dunagan.

The main bottleneck the company faces is educating OEM engineers about why, when and how to use composites in place of metals.

“Cars and car parts are traditionally made from metal, and OEMs are very well versed in designing with metal and stamping out metal parts. Many have their own stamping operations too, making the decision to use composites even more challenging,” he explained.

On the other hand, the automotive industry is in the era of sustainability, Teijin Automotive Technologies is also striving to reduce its environmental impact. The company is currently engaged in a variety of research projects, including life cycle analysis and recycling processes.