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AIMPLAS developing transformation processes for thermoplastic composites that can replace metal components of battery systems

The VETERIA21 Project, funded by the Valencian Regional Government and implemented by AIMPLAS, will develop new, more efficient transformation processes for thermoplastic composites so they can be used to replace the metal content of electric vehicle batteries.


These materials ensure a major reduction in vehicle weight, which extends battery life. They are also in line with the circular economy due to their recyclability.

Currently made of stainless steel and aluminium, li-ion battery modules are big and heavy: they account for from 20% to 30% of vehicle weight.

In general, 73% of vehicle weight corresponds to the metal components. Thermoset composites are therefore a lightweight alternative for battery casings. However, their recyclability and production rate work against them. For this reason, thermoplastic composites represent a good alternative.

—Begoña Galindo, AIMPLAS Sustainable and Future Mobility Group Leader

Thermoplastic composites have become a trend in vehicle weight reduction for several reasons other than their reduced weight: mechanical resistance, adaptability to different manufacturing processes, short manufacturing cycles, ability to be combined with other materials, weldability, easy recyclability and adaptability to the circular economy.



This represents a good start to reducing weight and improving efficiency in EVs.
There are many others; how about replacing the heavy 12 volt lead/acid battery. It's interesting that Tesla is leading the way and making the change across their whole lineup.
Another upgrade would be to use axial flux motors; there are many parts of an EV that could be upgraded...how about rear drive dual hub motors with vectoring instead of a differential and reduction gearing?; How about removing the AC traction battery charger from on board to direct DC charging in the garage?, etc.

How about removing the AC traction battery charger from on board to direct DC charging in the garage?

That's easy.  There are too many places without DC chargers.  You're still going to want to have a "convenience cord" so you can charge from a standard NEMA outlet if that's all that's available.  You can't do that without an on-board charger.

I am pondering the addition of a 12-volt trickle charger connected to the J1772 A/C wiring to keep the tiny lead-acid battery charged when the car is plugged in but hasn't been used for a while.  I've had the car die when it just sat in the garage too long and the standby loads killed the 12-volt battery; the DC-DC converter only works when the car is on.  I'd have to find a 120/240 volt trickle charger, though.

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