Expected benefits and areas for verification

Objectives

The overall goal of this study is to develop a demonstrator of a segment (size of a module or cell stack) of a lightweight steel-wood battery housing, where wood and steel is used in combination, so that the favourable properties of both materials can complement each other. The following advantages are expected and verified:

  • Excellent temperature-management
    through the combination and use of the advantages of both materials: steel has a high thermic conductivity. Thus, in combination with a water-cooling, it allows an active thermo-regulation for the cooling of cell stacks. Wood has a low thermic conductivity and can therefore prevent an unwanted heat loss. In this way, a zone-dependent and thus energy-efficient thermo-regulation can be ensured.
  • Improved crash behavior:
    Wood has a high energy absorption under compression. Using wood as a core material in metal profiles can prevent the profiles from bending and therefore helps to keep the flexural as well as the compressive rigidity high even at large strains. This way, the energy absorption in flexural and compressive load cases can be increased drastically. Wood laminates used in the bottom cover can absorb the deformation energy of hits and serve as an underbody protection.
  • Improved vibration damping:
    Using the vibration-damping properties of wood, beadings in the battery base and cover are not necessary and a completely smooth underbody can be produced.
  • Excellent control of thermal propagation:
    Through the formation of a pyrolysis layer (burn rate 0.6-1.0mm/min) in combination with a low thermal conductivity (0.14 W/(mK)), whereas the pyrolysis layer has an even lower thermal conductivity (0.0035 W/(mK)), the propagation of a thermal runaway can be impeded for a long time.
  • Reduced installation space and weight due to functional integration:
    By combining functions (heat insulation, vibration-damping, impact energy absorption, elastic resilience and fire restraining), installation space and weight can be reduced at relatively low costs.
  • Improved ecological footprint:
    Wood contributes to an improved ecological footprint due to its storage of greenhouse gases and substitution effects.

Research tasks

To achieve the described objectives, research tasks concerning the following main topics have to be conducted:

  1. Joining technology:
    Powerful adhesive systems contribute significantly to the overall costs. Thus, alternative, cost-efficient and powerful ways of connecting wood and metal are investigated.
    • Adhesive-free joining techniques (form fit, frictional connection, integrated connections using beading, ribs etc.)
    • Mechanical fasteners made of polymeric materials (friction welding dowels and rivets)
    • Investigation of the alternative connection technologies regarding technical properties, costs and possibilities of serial production
  2. Wood modification:
    Wood has no unlimited resistance to biotic and abiotic stresses. Through wood modification, these properties can be changed. However, wood modifications also increase costs. Therefore, in Bio!LIB, such modifications shall only be used locally (e.g. in the outer layers):
    • to impede metal corrosion at the interface between metal and wood (thermally modified wood),
    • to increase the durability by using modified veneers (acetylation, furfurylation, high pressure laminates),
    • to further reduce the thermal conductivity coefficient (delignification),
    • and to increase the flame retardant effect (sodium silicate, salts).
    • The technical properties, costs and possibilities of serial production of modified wood-laminates are investigated.
  3. Fire performance in battery housings:
    • Reaction of gases, which are produced during wood charring, with the leaking gases and liquids of a burning Li-Ion-cell
    • Outgassing behavior, burn rate and thermal conduction coefficient - with and without oxygen restriction ("Tightness" of the battery housing)
  4. Ecological footprint:
    Steel and wood belong to the more ecological materials. However, both the production and the EoL-phase still offer room for improvement. Approaches to reduce the necessary amount of energy during production (drying plants, hot pressing, ..) and to maintain the seperability of materials are explored.
Contact
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Vehicle Safety Institute

Inffeldgasse 23/I
8010 Graz
AUSTRIA

Tel.: +43 316 / 873 30301
Fax: +43 316 / 873 30302

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