Development of Hybrid Polymer Composites with Improved Thermal Properties and Investigation of Their Mechanical Properties for Battery Module Case Manufacturing in Electric Vehicles

Abstract

In the realm of transportation sustainability, electric vehicles play a crucial role. The aim of this article was to create a hybrid composite material using polymers that would have enhanced heat conductivity and impact resistance. This material would be used to manufacture battery casings for electric cars. Polyamide 6 (PA6) was selected as the matrix material owing to its convenient manufacturing process and extensive application. Additionally, hexagonal boron nitride (hBN) and graphene nanoplatelets (GnP) were incorporated to enhance the thermal conductivity of the matrix. Furthermore, to enhance the structural integrity against potential ground impact damage, a styrene-ethylene-butylene-styrene (SEBS) elastomer reinforcement was used alongside the aforementioned elements. Following the extrusion and injection molding processes, the composites underwent mechanical testing using three-point bending and Izod impact tests. When 30 wt.% hBN was added, there was a 22% improvement in flexural strength and a 101.1% improvement in flexural modulus. Similarly, when 2.5 wt.% GnP was added, there was a 14.1% improvement in flexural strength and a 55.6% improvement in flexural modulus. Then, thermal analyses were performed through Differential Scanning Calomerimetry (DSC) and thermal conductivity measurements. Furthermore, it was observed that the addition of 30 wt.% hBN resulted in a significant increase of 194.3% in thermal conductivity. Subsequently, the fracture surfaces were subjected to scanning electron microscopy (SEM) in order to investigate the underlying causes of material damage subsequent to failure. The Halpin-Tsai (HT) micro-mechanical model was used to estimate the modulus of the composites.

Keywords

• Electric cars
• Battery case
• Hexagonal boron nitride
• Graphene nanoplatelets
• Failure mechanisms

Elektrikli Araçlarda Batarya Kutusu İmali İçin Termal Özellikleri İyileştirilmiş Hibrit Polimer Kompozitlerin Geliştirilmesi ve Mekanik Özelliklerinin İncelenmesi

Abstract

Elektrikli araçlar, ulaşımın sürdürülebilirliği için oldukça önemlidir ve içten yanmalı motorlu araçlar gibi fosil yakıtlar kullanmadıklarından çevreye zararlı gaz salınımında bulunmamaktadırlar. Elektrikli araçların bu özelliğinden faydalanmak için kullanımlarını teşvik etmek amacıyla çeşitli çalışmalar yapılmaktadır. Bu çalışmada, elektrikli araçlardaki batarya kutusu üretimi için termal iletkenliği ve darbe direnci iyileştirilmiş polimer esaslı hibrit kompozit bir malzeme geliştirilmesi amaçlanmıştır. Yaygın kullanımı ve üretim kolaylığı nedeniyle matris olarak Poliamid 6 (PA6) kullanılmış, termal iletkenliğini artırmak için ise hegzagonal bor nitrür (hBN) ve grafen nanopulcuk (GnP) kullanılmıştır. Bu malzemelere ek olarak, zeminden kaynaklanabilecek potansiyel darbe hasarı durumunda dayanıklılığı artırmak için bir stiren-etilen-bütadien-stiren (SEBS) elastomer takviyesi eklenmiştir. Kompozitler ekstrüzyon ve enjeksiyon kalıplama ile üretildikten sonra, numunelerin mekanik testleri; üç nokta eğme ve Izod darbe dayanımı testleriyle yapılmıştır. Kütlece %30 hBN kullanılması durumunda eğilme dayanımı ve modülünde sırasıyla %22 ve %101.1’lik bir iyileşme sağlanmıştır. Kütlece %2.5 GnP kullanılması durumunda eğilme dayanımı ve modülü değerlerinde sırasıyla %14.1 ve %55.6’lık bir iyileşme sağlanmıştır. Kütlece %5 SEBS kullanıldığında darbe dayanımını değerinin %58.5 arttığı tespit edilmiştir. Ayrıca termal karakterizasyon için diferansiyel taramalı kalorimetre analizleri ve termal iletkenlik ölçümleri yapılmıştır. Kütlece %30 hBN eklendiğinde termal iletkenliğin %194.3 arttığını görülmüştür. Daha sonra, malzemelerde hasar mekanizmalarını incelemek için kırılma yüzeyleri taramalı elektron mikroskobuyla (SEM) incelenmiştir. Son olarak, Halpin Tsai (HT) yaklaşımı kullanılarak kompozitlerin mikromekanik modelleri kurulmuştur. Bu modellerin doğruluğunu tespit etmek için ise deneysel verilerle karşılaştırma yapılmıştır.

Keywords

• Elektrikli araçlar
• Batarya kutusu
• Hegzagonal bor nitrür
• Grafen nanoplaka
• Hasar mekanizmaları

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