The European Union's Optimized Energy Management and Use (OPTEMUS) project aims to reduce energy consumption and optimize vehicle space, taking into account the space, cost, and complexity requirements of the vehicle, and aims to solve the electric problems caused by the limited battery capacity. Limited car mileage.
OPTEMUS aims to develop many innovative core technologies (integrated thermal management system solutions, consisting of compact refrigeration units and compact air-conditioning heating and ventilation units, battery housings, and insulation parts. This solution can be used as heat storage, energy storage equipment, thermal energy Management control unit, regenerative shock absorber composition) and complementary technologies (competitive technologies) and intelligent control (eco-driving, environmentally friendly route strategy, predictive cockpit preset strategy, minimum energy consumption, electric management strategy).
The OPTEMUS project involves a power battery with a thermal storage function. The Fraunhofer LBF Institute for Structural Durability and System Reliability has participated in the design of this product.
This phase change material composite system developed by Fraunhofer LBF can be used for pre-adjusting temperature-sensitive cells, suitable for severe cold climates, and the use of a heat shield ensures that it will work at the optimal operating temperature. Operation to extend battery life. It is worth mentioning that the design eliminates the need for active temperature control.
Conversely, the design can also avoid the unnecessary unwanted heat of the battery showing an upward trend in the short term, for example, when the battery is fast charging.
In order to ensure thermally decoupled phase change composites, avoid environmental damage and facilitate process control, Fraunhofer LBF researchers have adopted a new method to make thermally insulated, high-strength battery covers.
This part is based on foam plastic injection-integrated polymer foam (SABIC PP15T1020), which can be fused with high-strength thermoplastic fiber plastic composite material (TP-FKV) after adopting the hybrid production process, which improves the thermal insulation performance of the material.
To investigate and evaluate different types of polymer foams and foam morphologies to improve thermal insulation, researchers designed a cavity analysis method based on computer tomography 3D image technology.
Due to the low strength and hardness of the polymer foam, the researchers coated the material with TP-FKV to ensure it can safely carry the working load of the battery. To this end, LBF researchers produced a thin unidirectional tapes (UDMAX from SABIC) with a thickness of 0.25 millimeters. Before injecting the integrated foam, the hybrid manufacturing process was used to adjust its three dimensions, and then It acts as a core layer between two laminate cover layers.
The sandwich structure has the following advantages: large weight reduction potential, high bending performance, and strong impact resistance. In addition, the material also plays a protective role on the surface, preventing the intrusion of foreign substances, and plays an important role in battery pack applications.
Both of the above materials and structural concepts can be used in mass production.