The Automotive composites Alliance is pushing thermoset plastic composites for a wide variety of applications in hybrid cars, including modules that contain the battery pack, electronic controller and wiring harness. In the US the modules are typically made of several metal stampings which are assembled. Use of composites could reduce the module to two pieces with major savings in weight as well as tooling investment. “Unlike metal, composites don’t conduct electricity, therefore providing an extra safety advantage,” says the Alliance report. “They also won’t corrode and allow integrated airflow cooling in the module’s tunnel, all adding to longer battery life.”
Oak Ridge National Laboratory has developed a surface preparation method to improve joining carbon composites with aluminum, with potentially far-reaching ramifications for high-volume industrial applications.
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