SABIC Completes First Molding Trial of Top Battery Cover Tool, Technology Displayed at Battery Show Europe

As the industry continues its shift toward electrification and OEMs push on in their search for the most efficient and effective battery solutions, SABIC is leading the charge by producing thermoplastic, fire retardant materials that reduce the complexity, weight and cost of the entire battery pack. Most recently, SABIC announced the successful first molding trial of a EV battery pack top cover tool. 

Under SABIC’s BLUEHERO™ initiative, the company is demonstrating a solution for the manufacturability of large-part EV battery components through thermoplastic injection molding. After initial molding trial tests, the battery top cover tool successfully produced a series of positive results, including:

• Clear split line and perfect holes
• Smooth opening and closing of the tool
• Excellent surface finishing
• Flat parts
• A smooth ejection process (no difficulties de-molding)

Following the encouraging results of this molding trial test, the SABIC team will continue to demonstrate the feasibility of low pressure injection molding technologies to manage the clamp force as well as warpage reduction. Additionally, a focus is to fulfill industry requirements relating to dimensional tolerance and limited design space. 

The battery top cover tool provides advantages for EV batteries that go beyond reduced complexity and lightweighting. The specific injection molding and injection compression molding process used by SABIC can lower carbon emissions and energy usage, reducing environmental impact. Beyond that, the materials in the top covers include fire-retardant thermoplastics that as well contribute to thermal insulation and increased functional integration of the battery pack.

This specific form of injection molding, which caters to the large size and functionality of the top cover, is an approach that is new to the industry and suitable to cover the high-volume production needs of the future for EVs. Through its growing expertise in the EV space and thermoplastic capabilities, SABIC is continuing to demonstrate the feasibility of large part injection molding processes for EV battery pack top cover components. 

SABIC attended the 2023 Battery Show Europe in Stuttgart, Germany where the team connected with industry peers and customers as well as put its latest, innovative electrification solutions on display, including the top cover tool. 

Attendees and customers alike praised the top cover tool for its fire suppression performance, weight savings and large part processability.