IDI International launches material solution for EV battery covers
IDI Composites International is introducing FLAMEVEX, a new family of fiber reinforcements and resins designed specifically for the manufacture of battery enclosure systems.
Share
![IDI Composites International EV battery enclosure](https://d2n4wb9orp1vta.cloudfront.net/cms/brand/CW/2020-CW/cw-jec2020-preview-IDI.png;maxWidth=720)
IDI Composites International EV battery enclosure manufactured with FLAMEVEX. Source | IDI
IDI Composites International (Noblesville, Ind., USA) is introducing FLAMEVEX, a new family of fiber reinforcements and resins designed specifically for the manufacture of battery enclosure systems for the electric vehicle (EV) and new energy vehicles (NEV) market.
The FLAMEVEX family of products, which include chopped glass fibers combined with either unsaturated polyester (UPR) or a combination of UPR and vinyl ester, has been used on battery packs that have passed the stringent Chinese Standard GB/T 31467.3 test, commonly known as the “Chinese bonfire test.” FLAMEVEX, says IDI, offers designers a strong, lightweight and cost-effective alternative to steel and aluminum materials traditionally used to enclose battery packs in EVs and NEVs.
Ramon Rodriguez-Irizarry, vice president and group director for electric vehicle market development at IDI, notes that EV battery pack design, configuration and location are currently not standardized and vary greatly from OEM to OEM. Because of this, the cost, dimensions, wall thickness and flame-retardant requirements of battery pack enclosures vary as well. FLAMEVEX, therefore, is being offered by IDI as a custom-compounded combination of fibers, resins and fillers designed to meet the customer’s application specific requirements.
FLAMEVEX is produced by IDI in a format that allows it to be processed like a sheet molding compound (SMC), but Rodriguez-Irizarry is quick to point out that the bespoke nature of the FLAMEVEX chemistry distinguishes it from traditional SMCs. He also notes that it will be possible, soon, to co-mold FLAMEVEX with continuous fiber preforms. Further, although the FLAMEVEX family currently uses chopped glass fiber, Rodriguez-Irizarry says carbon fiber is an option as well, but the cost penalty it brings limits its feasibility.
Working in collaboration with OEMs and Tier 1 partners, IDI FLAMEVEX materials have been used on battery packs which have passed the Chinese bonfire test at wall thicknesses as small as 2.5 mm.
“Thermoset composites represent an ideal replacement for metals in these kinds of battery enclosures,” noted Yves Longueville, general manager for IDI Composite Materials (Shanghai) - China. “Thermoset materials can be formed into complex shapes and they are also strong and lightweight. Beyond these benefits, a high level of fire performance distinguishes FLAMEVEX from traditional SMC composites,” Longueville explained. “FLAMEVEX maintains its impressive fire performance even at low thicknesses and without compromising the strength or moldability of the compound. It is the best choice for designers who aim to delight EV consumers with high-performing and affordable products.”
IDI says the market for EV and NEV vehicles is growing exponentially, with sales expected to double in 2020, reaching 4 million new cars globally. “As cost of ownership goes down, range increases and emissions requirements become tighter, electric and alternative fuel vehicles are only becoming more attractive to buyers,” says Rodriguez-Irizarry. “With FLAMEVEX, we’re not only helping to meet a need for OEMs and designers, we’re introducing a material that contributes to the strength, safety and affordability of this next generation of vehicles for consumers around the world.”
IDI Composites International says FLAMEVEX is available internationally via its locations in the United States, Mexico, Europe and Asia.
Related Content
Graphene-enhanced SMC boosts molded component properties
CAMX 2023: Commercially sold GrapheneBlack SMC from NanoXplore increases part strength, stiffness and provides other benefits for transportation, renewable energy, energy storage and industrial markets.
Read MorePly stacking, cutting process optimized via automation, smaller footprint
CAMX 2024: Schmidt & Heinzmann customers are able to produce SMC or dry fiber fabric stacks more efficiently thanks to the AutoCut Pick&Place system.
Read MoreImproving carbon fiber SMC simulation for aerospace parts
Simutence and Engenuity demonstrate a virtual process chain enabling evaluation of process-induced fiber orientations for improved structural simulation and failure load prediction of a composite wing rib.
Read MoreSMC simulation tool enhances design optimization
CAMX 2023: FiRMA, Engenuity’s new approach to SMC, uses a predictive technique that accurately reflects material properties and determine the performance range an SMC part or structure will exhibit.
Read MoreRead Next
The next-generation single-aisle: Implications for the composites industry
While the world continues to wait for new single-aisle program announcements from Airbus and Boeing, it’s clear composites will play a role in their fabrication. But in what ways, and what capacity?
Read MorePlant tour: Teijin Carbon America Inc., Greenwood, S.C., U.S.
In 2018, Teijin broke ground on a facility that is reportedly the largest capacity carbon fiber line currently in existence. The line has been fully functional for nearly two years and has plenty of room for expansion.
Read MoreCombining multifunctional thermoplastic composites, additive manufacturing for next-gen airframe structures
The DOMMINIO project combines AFP with 3D printed gyroid cores, embedded SHM sensors and smart materials for induction-driven disassembly of parts at end of life.
Read More