Built-in Features Lightweight Construction System Offers Key Additional Features for E-Mobility

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The Fraunhofer Institute for Microstructure of Materials and Systems (IMWS) demonstrates how lightweight construction with integrated functions and thermal management can work ...

The approach of the research project “InThElekt—Integral Thermoplastic Sandwich—Structure Components with Adapted Electronics for Electric Vehicles” is to replace conventional metal vehicle structures in electric cars with plastic parts manufactured using an innovative composite sandwich concept that incorporates electronic components. This reduces the vehicle’s weight and, as is well known, its energy consumption, which in turn increases the driving range, for example. However, a major challenge here is effectively dissipating the heat generated by the electronic components. This is because plastics typically have low thermal conductivity. The project partners—Elringklinger, EDAG Engineering GmbH, Simpatec GmbH, Symate GmbH, Netco Professional Services GmbH, Berliner Nanotest und Design GmbH, and Chemnitz University of Technology—have therefore collaborated with the IMWS to develop systems featuring novel encapsulation materials for electronics, thermal management, and interface concepts. Volkswagen, Hübers Verfahrenstechnik Maschinenbau, and Engel Austria participated as associated partners.

A Successful Combination of Material, Process, and Component

The focus of activities at the IMWS was on the development of lightweight structures using composite sandwich construction with continuous-fiber-reinforced thermoplastic face layers (organic sheets). Thermoplastic foam injection molding (TSG) was also used to produce foamed cores. These were combined with a process known as negative embossing to achieve the highest possible degree of foaming (TSG composite sandwich). This will enable the future production of lightweight components suitable for series production that meet structural and functional requirements for automotive applications. Using a lightweight assembly carrier as an example, the innovative technology, electrical function integration, and weight savings compared to the previous steel construction were successfully demonstrated, according to the report. Accordingly, one of the key challenges was to bring the complex interactions between material, process, and component geometry under control. The researchers explain that they therefore conducted a detailed investigation into how different material systems, foaming processes, expansion ratios, and process parameters (such as mold temperatures and holding times) affect the local foam structure and the associated mechanical properties of the sandwich composite. At the same time, suitable interfaces between structural and electronic components, as well as new thermal management concepts, had to be developed.

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This is How a Meaningful Demonstrator Was Created

As part of extensive campaigns, various test and demonstration structures were then designed. These were implemented using tooling and examined from a process engineering perspective. To this end, a complex test mold for foam injection molding and the integration of organic sheet material, as well as an automation system using a robotic gripping system, were developed. Various experimental studies on physical and chemical foaming provided reliable data on foam structure, component quality, and the reproducibility of part production. The rheological properties of the selected injection-molding compounds and the processing behavior of the thermoplastic tape face layers were thoroughly characterized as a function of process parameters. The resulting mechanical properties of the sandwich structures and boundary layers were also closely examined. Non-destructive testing methods (X-ray computed tomography and ultrasound) were also employed. These were used to analyze in detail aspects such as porosity, cell distribution, cover layer structure, and local structural quality. Mechanical tests and simulation-based design approaches also enabled a targeted evaluation of the structural behavior, as the researchers note.

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