MPDB® Pocket Profile Cooling
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SPE Award 2024 - 1st place in the “enabler technology” category
MPDB® Pocket Profile Cooling Technology
Raw material manufacturer: AKRO-PLASTIC GmbH
Tool manufacturer: Solidtec GmbH
Parts manufacturer: Erwin Quarder Systemtechnik GmbH
Other parties involved: Erbslöh Aluminum GmbH
MPDB® Pocket Profile Cooling Technology is a highly innovative solution that cuts costs, reduces tolerances and conserves resources. It enables the radial circumferential connection of plastic end pieces to aluminum multiport profiles (MPPs) using the MPDB® process. This technology is used in the cooling of cylindrical and prismatic battery cells in electric vehicles (BEVs).
In contrast to the current state of the art, in which end pieces are milled from aluminum and then brazed in large vacuum furnaces, the MPDB® process offers considerable advantages. It enables a helium-tight and long-term stable connection between metal and plastic. The end pieces, which were previously milled from solid material, can now be produced efficiently and cost-effectively using the injection molding process in multiple cavities. The manufacturing process is extremely fast and takes less than seven seconds, resulting in considerable energy and cost savings.
Source spe-CE.de
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Material selection
The polyketone used is AKROTEK® PK VM 30 black (4896), which, thanks to its extremely high elongation, does not plasticize over the entire service life of the product and remains in the linear-elastic range. This virtually eliminates creep processes under changing pressure and temperature loads. The material is also characterized by excellent long-term resistance to glycol/water mixtures. In the event of a thermal runaway, it offers additional protection as it does not melt but cross-links and becomes thermoset, creating a protective barrier.
Component production
In component production, the plastic parts are injection molded and prepared in advance. The cut-to-length, straight aluminum pocket profile is provided with a micro- and nanostructure at the ends. The ends of the aluminum profile are then heated locally to the melting temperature of the plastic and joined to the prefabricated plastic end pieces. This process takes less than seven seconds.
The local heating and the automatic joining process can compensate for length tolerances of the aluminum profile and reduce the overall tolerances. As a result, less thermal interface material is required for battery assembly, which both increases performance and reduces weight. The plastic end pieces are also up to 50% lighter and can be cost-effectively equipped with additional functional elements such as gripping positions for automatic handling, sealing elements or even sensors.
A new electrically insulating UV coating enables lower layer thicknesses compared to powder coating, which also reduces costs and weight.
The biggest challenge was to gain customer acceptance for the new MPDB® technology. We achieved this by producing prototypes and successfully carrying out long-term tests, detailed analyses and validations. Thanks to these comprehensive tests and positive results, we were able to gain the trust of our customers. The first product in this innovative technology family will go into series production in 2025.
