CRASHWORTHINESS OF C-SMC : A STRUCTURAL BATTERY CASE FOR AUTOMOTIVE APPLICATION

The drive towards electrification has brought a new series of challenges in the automotive world. The need of supporting and protecting battery modules requires the fulfilment of contrasting objectives. These are to provide sufficient robustness and stiffness at a low weight while at the same time being cost effective. Carbon Fiber Sheet Moulding Compounds (CF-SMC) are a promising class of materials with the potential to replace aluminium and steel in many structural automotive applications. CF-SMC materials are stiff, light and they present the possibility to be formed with low cycle times through pressing. This opens up the possibility to automate the production process, further reducing the price per component. In this paper we investigate the possibility of using such material to realize a battery protection system that integrates the structural, crash and thermal function in one piece. A mechanical simulation procedure was adopted to model the mechanical behaviour under normal as well as crash events. Material tests were performed to assess the dynamic response of the material. Advanced non-linear material models and damage evolution methods based on experimental data were used. The positive outcome of the simulations exposed the full potential of adopting C-SMC materials as a choice for structural parts in electric vehicles, resulting in a lightweight although mechanically sound battery casing