• Design & Manufacturing
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• v.17 no.1
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• pp.48-55
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• 2023

In this study, on the structure simulation for manufacturing a high strength/light weight 48V battery housing for a mild hybrid vehicle was conducted. Compression analysis was performed in accordance with the international safety standards(ECE R100) for existing battery housings. The effect of plastic materials on compressive strength was analyzed. Three models of truss, honeycomb and grid rib for the battery housing were designed and the strength characteristics of the proposed models were analyzed through nonlinear buckling analysis. The effects of the previous existing rib, double-sided grid rib, double-sided honeycomb rib and double-sided grid rib with a subtractive draft for the upper cover on the compressive strength in each axial direction were examined. It was confirmed that the truss rib reinforcement of the battery housing was very effective compared to the existing model and it was also confirmed that the rib of the upper cover had no significant effect. In the results of individual 3-axis compression analysis, the compression load in the lateral long axis direction was the least and this result was found to be very important to achieve the overall goal in designing the battery housing. To reduce the weight of the presented battery housing model, the cell molding method was applied. It was confirmed that it was very effective in reducing injection pressure, clamping force and weight.

• Korean Journal of Poultry Science
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• v.39 no.4
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• pp.261-267
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• 2012

Different housing systems have considerable influence on performance in poultry production. Therefore, the present study was undertaken to investigate the impact of different housing systems on the performance, bone mineral density and egg yolk fatty acid composition in laying hen. Hy-line brown pullets (n=450) of 12 weeks age were randomly divided into 3 housing systems with 6 replicates of 25 birds in each room. A diet with 2,750 kcal/kg ME and 16.5% CP was assigned to all birds. The pullets provided free access to feed and water. Significantly (P<0.05) higher values for egg production, egg mass and feed conversion efficiency were found in battery cages, however egg weight, egg shell color and breaking strength was remarkably (P<0.05) higher in floor system. The albumin height and Haugh unit were significantly higher (P<0.05) in battery cages which was statistically similar to aviary housing system. The egg yolk fatty acids concentration of linoleic acid and linolenic acids were significantly higher in aviary and in floor system, respectively, however both values were lower in battery cages. Saturated and unsaturated fatty acid content (%) in egg yolk did not influence by any housing systems. Bone mineral density was significantly higher (P<0.05) in floor and aviary housing system than that of battery cage system. It was concluded that in battery cages the egg production and composition maximized, however higher bone mineral density and yolk fatty acids content can be improved in the laying hen reared on floor and aviary housing systems.

• Journal of Powder Materials
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• v.31 no.4
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• pp.329-335
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• 2024

As the demand for electric vehicles increases, the stability of batteries has become one of the most significant issues. The battery housing, which protects the battery from external stimuli such as vibration, shock, and heat, is the crucial element in resolving safety problems. Conventional metal battery housings are being converted into polymer composites due to their lightweight and improved corrosion resistance to moisture. The transition to polymer composites requires high mechanical strength, electrical insulation, and thermal stability. In this paper, we proposes a high-strength nanocomposite made by infiltrating epoxy into a 3D aligned h-BN structure. The developed 3D aligned h-BN/epoxy composite not only exhibits a high compressive strength (108 MPa) but also demonstrates excellent electrical insulation and thermal stability, with a stable electrical resistivity at 200 ℃ and a low thermal expansion coefficient (11.46×ppm/℃), respectively.

• Corrosion Science and Technology
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• v.21 no.5
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• pp.348-359
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• 2022

Interest in electric vehicle is on the rise due to global eco-friendly policies. To improve the efficiency of electric vehicles, it is essential to reduce weights of components. Since electric vehicles have various electronic equipment, the research on stray current corrosion is required. In this research, a galvanostatic corrosion experiment was performed on 6061-T6 Al alloy for electric vehicle battery housing using chloride concentration and applied current density as variables in a solution simulating an acid rain environment. As a result of the experiment, when chloride concentration and applied current density were increased, corrosion damage became larger. In particular, pitting damage was dominant at an applied current density of 0.1 mA/cm². Pitting damage over the entire surface was found at a current density of 1.0 mA/cm². In conclusion, chloride concentration had a relatively large effect on localized corrosion. The applied current density had a great effect on uniform corrosion. However, in the case of applied current density, localized corrosion was also greatly affected by interaction with chloride.

• Corrosion Science and Technology
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• v.21 no.2
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• pp.147-157
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• 2022

Electrochemical characteristics and damage behavior of 6061-T6 aluminum alloy used as a battery housing material for electric vehicles were investigated in solution simulating the acid rain environment with chloride concentrations. Potentiodynamic polarization test was performed to analyze electrochemical characteristics. Damage behavior was analyzed through Tafel analysis, measurement of damage area, weight loss, and surface observation. Results described that corrosion current density was increased rapidly when chloride concentration excceded 600 PPM, and it was increased about 7.7 times in the case of 1000 PPM compared with 0 PPM. Potentiodynamic polarization experiment revealed that corrosion damage area and mass loss of specimen increased with chloride concentrations. When chloride concentration was further increased, the corrosion damage area extended to the entire surface. To determine damage tendency of pitting corrosion according to chloride concentration, the ratio of damage depth to width was calculated. It was found that the damage tendency decreased with chloride concentrations. Thus, 6061-T6 aluminum alloy damage becomes larger in the width direction than in the depth direction when a small amount of chloride is contained in an acid rain environment.

• Journal of the Korea Convergence Society
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• v.13 no.4
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• pp.331-337
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• 2022

Manufactured thermoplastic composite materials to replace the metal materials used as battery housing materials for electric vehicles with lightweight materials. As the matrix material, nylon 6 which is a polymer material was used. Boron Nitrate(BN), which has high thermal conductivity, was used to provide heat dissipation performance. The heat dissipation characteristics of the thermally conductive polymer composite material according to the BN content and particle size were analyzed. The thermal conductivity value increased as the filler content increased, and composite materials particle size of 60 to 70㎛ and BN content of 50%, the thermal conductivity was 1.4 W/mK. The larger the particle size, the wider the inter-particle interface contact surface, which means that a thermal path was formed. wider the interfacial contact surface between the particles, and the thermal path was formed. A battery housing was manufactured using the manufactured thermally conductive polymer composite material, and the temperature change during charging and discharging of the cell was observed, and the possibility as a substitute material for the battery housing was confirmed.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.15 no.1
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• pp.53-61
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• 2019

The seismic capacity of electric cabinets in Nuclear Power Plants (NPPs) should be qualified before installation and be maintained during operation. However it can happen that identical devices cannnot be produced for replacement of devices mounted in electric cabinets. In case of when no In-Cabinet Response Spectrum (ICRS) is available for new devices, ICRS can be generated by using Finite Element Analysis (FEA). In this study we investigate structural response and ICRSs of battery charger which is supplied to NPPs. Test results on the battery charger are utilized in this study. The response is measured by accelerometers installed on the housing of the battery charger and local panels in the battery charger. Numerical analysis model is established based on resonant frequency search test results and validated by comparison with 2 types of earthquake testing results. ICRSs produced from the numerical model are compared with measured ICRSs in the seismic tests. Developed analysis model is a simple reduced model and anticipates ICRSs quite well as measured response in the tests overall despite of its structural limitation.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.12
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• pp.113-118
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• 2020

Recently, eco-friendly electric motorcycles have been considered to replace aging gasoline motorcycles to reduce the amount of suspended fine dust in air. However, existing rechargeable battery-powered electric motorcycles have been found unacceptable by users because of their many limitations, such as long charging time, short travel distance per charge, and low driving speed. To overcome the drawbacks of conventional electric motorcycles, this paper proposes an exchangeable battery-powered electric motorcycle and a new frame shape for housing the exchangeable battery. The proposed frame is similar to that of current electric motorcycles; however, the shape and position of the saddle support, battery, and controller mount section are redesigned. The safety of the presented frame is verified through static and dynamic analyses using ABAQUS. In particular, the dynamic analysis is conducted under the most extreme condition among the various operating situations, thus confirming the robustness of the proposed frame design.

• Design & Manufacturing
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• v.17 no.3
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• pp.55-60
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• 2023

The fiber-reinforced plastics and cellular injection molding process can be used to efficiently reduce the weight of battery housing components of mild hybrid electronic vehicles(MHEV) made of metal. However, the fiber orientation of fiber-reinforced plastics and the growth of foaming cells are intertwined during the injection molding process, so it is difficult to predict the mechanical properties of products in the design process. Therefore, it is necessary to evaluate the mechanical properties of the materials prior to the efficient stiffness design of the target product. In this study, a study was conducted to evaluated the mechanical properties of fiber reinforced cellular injection-molded specimens. Two types of fiber-reinforced plastics that can be used in the target product were evaluated for changes in tensile properties of cellular injection-molded specimens depending on the foaming ratio and position from the injection gate. The PP and PA66 specimens showed a decrease of tensile modulus and strength of approximately 30% and 17% depending on the foaming ratio, respectively. Also, the tensile strength decreased approximately 26% and 17% depending on the position from the injection gate, respectively. As a result, it was confirmed that the PP specimens have a significantly mechanical property degradation compared to the PA66 specimens depending on the foaming ratio and position.

• Current Applied Physics
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• v.18 no.11
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• pp.1451-1457
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• 2018

Injection compression molding (ICM) is an advantageous processing method for producing thin and large polymeric parts in a robust manner. In the current study, we employed the ICM process for an energy-related application, i.e., thin and large polymeric battery case. A mold for manufacturing the battery case was fabricated using injection molding. The filling behavior of molten polymer in the mold cavity was investigated experimentally. To provide an in-depth understanding of the ICM process, ICM and normal injection molding processes were compared numerically. It was found that the ICM had a relatively low filling pressure, which resulted in reduced shrinkage and warpage of the final products. Effect of the parting line gap on the ICM characteristics, such as filling pressure, clamping force, filling time, volumetric shrinkage, and warpage, was analyzed via numerical simulation. The smaller gap in the ICM parting line led to the better dimensional stability in the finished product. The ICM sample using a 0.1 mm gap showed a 76% reduction in the dimensional deflection compared with the normal injection molded part.