Pöppelmann K-TECH®: Highly precise, temperature-resistant, and reliably sealed plastic parts protect batteries of electric cars

Dimensional stability, optimal temperature and chemical resistance: With highly precise plastic components, Pöppelmann K-TECH® has established itself as a reliable supplier for electric vehicles.

For battery concepts in the field of e-mobility, especially high demands are placed on tightness and temperature resistance. Pöppelmann K-TECH® has been developing highly precise technical plastic parts for over a decade that meet these requirements. For sealing the products, the injection molding process of two-component liquid silicone rubber (Liquid Silicone Rubber/LSR) has proven effective.

Everyday-compatible battery concepts: Starting with E-SMART

The switch to electric vehicles is an important component of society's overall commitment to greater environmental and climate protection. To establish vehicles with electric drives, everyday-compatible battery concepts are needed. Pöppelmann K-TECH® has been developing highly precise technical plastic solutions for over a decade, characterized by properties such as heat resistance, low weight, compact design, and high precision. The plastics specialist can now offer particularly safe and economical solutions for all common cell variants on the market. In 2011, the large-scale project E-SMART was launched together with Daimler's subsidiary ACCUmotive. Pöppelmann K-TECH® took over the development of technical individual components made of plastic.

Special requirements, innovative solutions from Pöppelmann K-TECH®

The cell, insulation, and current collector frame developed for the E-SMART are characterized by high flame retardancy, a very compact design for limited installation space, as well as high precision and dimensional stability. The products are manufactured as a hard-soft component composite, also known as 2K. The hard component provides stability to the frame, while the soft component ensures a gentle embedding of the battery cells. The design of the cell frames ensures, among other things, that there are no undesired reactions during possible cell growth during charging and discharging of the batteries. The flame-retardant material according to UL94V0 offers the highest safety standards. Most E-SMARTs of the ED3 generation, in which these components were installed, are still in use – with apparently well-protected batteries. In a new e-vehicle project for a luxury limousine manufacturer, Pöppelmann K-TECH® is again responsible for developing the cell frames.

Sealing with LSR: Excellent properties, perfectly tailored to e-mobility

When sealing the technical components used in the battery technology of e-vehicles, the highest requirements also apply. Here, technical plastic solutions are needed that must demonstrate extreme durability. Pöppelmann K-TECH® has expanded its range to include the injection molding of two-component liquid silicone rubber (Liquid Silicone Rubber/LSR). The 2K-LSR process is particularly heat and chemical resistant and exhibits excellent properties in pressure deformation tests. Additionally, it impresses with good weathering, aging, and UV resistance, as well as neutral odor. Another advantage is the secure sealing even with high tolerances. This technology allows different materials to be overmolded in a process-safe and fully automatic manner. Additional assembly steps are eliminated. Depending on the material pairing, a chemical bond between the hard and soft components can be achieved in addition to the sealing function. The fully automatic, single-stage process achieves particular cost-effectiveness at high production volumes.

All from a single source: From development to series production

With more than a decade of experience, Pöppelmann K-TECH® possesses extensive know-how in e-battery concepts. The plastics specialist combines all process chain steps under one roof: from design through rapid development tools and in-house toolmaking, which includes prototype or pre-series production with state-of-the-art in-house 3D printers, to efficient high-end series manufacturing. Customers benefit from comprehensive service, characterized by quick response times and high flexibility in fulfilling special requests. This enables Pöppelmann K-TECH® to develop the optimal solution quickly for complex and demanding requirements in the field of battery technology for e-vehicles.