EXPERIMENTAL INVESTIGATION ON HYBRID FIBRE BASED POLYPROPYLENE COMPOSITES FOR BATTERY FIRE RETARDATION
Team Member
VISHWA J (113218102024)
PUGALENDHI S (113218102019)
ANAND S (113218102005)
MADHAVAN M (113218102014)
PROJECT GUIDE
Dr. V. CHANDRAN M.Tech, Ph.D ASSOCIATE PROFESSOR
VELAMMAL ENGINEERING COLLEGE �(SURAPET, CHENNAI-66)
ABSTRACT
The aim of this project is to develop a novel composite material for battery fire retardation purposes. In this project, experimental and investigation of different compositions of carbon fibre (CF) and basalt fibre with combination of polypropylene (PP) at 5wt%, 10wt% along with epoxy, in order to improve the characteristics of the battery casing. This composite fabrication process is carried out by hand lay-up method and compression moulding. Each specimen is subjected to tensile, flexural and hardness testing. The scanning electron microscope (SEM) carried out to find out the microstructure of hybrid fibre based composites.
The results showed that, sample C showed better results which were made of 3 layers of carbon fibre and 4 layers of basalt fibre with 5wt % of polypropylene particles. The comparison study was also carried out with a pure polypropylene sheet. With these results, the best suitable material composition is selected (Sample C) for analysing the real time performance of the battery casing.
OBJECTIVES
LITERATURE SURVEY
S. No. | Article title | Author | Year | Inference |
1 | The Mechanical properties of hybrid composites reinforced by carbon and basalt | Guangyong Sun, Et al. | 2018 | We can see that a composite with a higher number of carbon layers gives high tensile strength and a composite with a higher number of basalt fibre layers results in high flexural strength. |
2 | A Review of Battery Fires in Electric Vehicles | Peiyi Sun, et al. in | 2019 | The fire risk and hazard of Li-ion batteries (LIB) are particularly serious in EVs, because of high demands in driving performance and charging speed, inevitable traffic accidents, and the increasing scale and energy density of battery packs. In the future, fire-protection systems with a better design should also be required for building sand parking spaces that contain a greater number of EVs and charging stations. |
3 | A review of lithium ion battery safety concerns | YuqingChen, et al. in | 2020 | Main strategies to meet these challenges focus on increasing the speed and uniformity of heat transfer in large, high-density batteries. However, increasing the mechanical reinforcement of LIBs to enhance their protection is also important, for example, adjusting outer casing materials to increase their impact resistance. Another solution would be to install batteries in parts of cars that are least affected during collisions and accidents. |
S. No. | Article title | Author | Year | Inference |
4 | Mechanical properties of hybrid composites reinforced by carbon and basalt fibers | Guangyong Sun, et al. | 2018 | Come to know Tensile, compressive, flexural value of Carbon reinforced basalt fibre |
5 | Materials for Electric Vehicle Battery Cells and Packs 2021-2031 | Dr James Edmondson, et al. | 2021 | Manufacturers are improving their battery designs, the mass of materials being used around the cells is steadily being reduced, allowing for a lighter battery pack or more cells to be used for the same mass. The choice of materials for several pack components also affects these improvements. More interest is being paid to composite enclosures for light-weighting, fire-retardant materials, thermal interface materials and much more |
6 | Physical, Thermal and technical Properties of Areca Fiber reinforced Polymer Composites – An Overview | Tamil Moli, et al. | 2020 | Know about the Different properties for different fibres |
7 | Study on the Battery Safety in Frontal Collision of Electric Vehicle � | Weigao Qiao, et al. | 2021 | The finite element model of battery case is established and its safety in frontal collision is analyzed emphatically which can be improved by adding cushion structure such as EVA foam and replacing steel with carbon fiber composite. |
IDENTIFICATION OF PROBLEM
Occasionally we can see that Electric vehicle leads to a fire accident at different places and also under different conditions such as:
• Indian Climatic conditions
• Overnight charging
• Malfunctioning BMS
• Mechanical abuse
In such accidents, Flame produced from the battery is spread to nearby areas, which leads to high risk and after propagation of flame it is difficult to quit the flame, so we are trying to discover a new carbon fibre composite to retard fire.
METHODOLOGY
Research
Material Selection
Purchasing
Fabrication of Samples
Testing
Analysis
Result
CARBON FIBER
EPOXY AND HARDNER
BASALT FIBER
POLYPROPYLENE
MATERIALS & METHODS
NYLON DIE
FORMULATION OF HYBRID COMPOSITES
4 Carbon Fiber
3 Basalt Fiber
3 Carbon Fiber
4 Basalt Fiber
The process is carried out by press moulting method, each sample has seven layers within it. The specimen are prepared in dimension of 15 x 30 cm.
SAMPLE | POLYPROPYLENE
| EPOXY RESIN+ HARDENER | CARBON FIBRE | BASALT FIBRE |
O | 100 wt% | - | - | - |
A | 5 wt % | 50 wt % | 26 wt % | 19 wt % |
B | 10 wt % | 50 wt % | 23 wt % | 17 wt % |
C | 5 wt % | 50 wt % | 19 wt % | 26 wt % |
D | 10 wt % | 50 wt % | 17 wt % | 23 wt % |
FABRICATION OF COMPOSITES
All the four fibre composites are fabricated by compression moulding method, for fabrication we used Nylon Die with (30cm X 30cm X 6mm) in dimension. The procedure for the fabrication is discussed below:
6. Then the upper layer of the mould is attached to the lower mould by nut and bolt for compression of the sample.
7. Then the working sample is rested for 24 hrs at room temperature for curing, after the complete curing, the sample is ejected out of the mould.
8. The final product will require additional work such as cutting away the unwanted pieces.
Final Stage Of Composite Fabrication
Fabricated Sample
RESULT DISCUSSION
TENSILE TEST
Tensile test is also known as tension test, In which a sample is subjected to a controlled tension until failure from this we can able to find out the tensile value of the material. We have done this test at Micro Lab, with a specimen size of (100mm X 15mm X 6mm) ASTM D638.
Fig. Tensile & Flexural Specimen
From the graph, we can observe that Sample B’s tensile value is higher than other samples. Sample B is made of 4 layers of carbon fibre and 3 layers of basalt layer with 10wt% of polypropylene.
FLEXURAL TEST
Flexural strength is the ability of the material to withstand bending forces applied perpendicular to its longitudinal axis. This test is carried out in Micro Lab, with a sample Size of (70mm X 20mm). ASTM D790 is used to determine the flexural strength of plastics and composites.
From the graph we can say that Sample C has the highest Flexural Strength among them, with this result we can observe that flexural strength increases on decreasing in polypropylene and the sample with high basalt fiber gives higher flexural strength on comparing with carbon fiber.
HARDNESS TEST
Hardness a test to determine the resistance a material exhibits to permanent deformation by penetration of another harder material. Brinell hardness BHN is the most commonly used test standards.
From the result, we can say that increase in polypropylene the hardness value is decreases. On the hardness test sample C gives the best result. Sample C is made of 3 layers of carbon fibre and 4 layers of basalt fibre with 5wt% of polypropylene.
SCANNING ELECTRON MICROSCOPE
The scanning electron microscope is used to capture the micro details of the sample, it is very useful to understand the bonding of layers, the presence of polypropylene between the layers, etc. SEM tests are tested at the SAIF/IITM laboratory.
From this SEM result we can see that polypropylene are present in between the fiber. So, we confirm that polypropylene mixed epoxy are well suited with the fiber.
POLYPROPYLENE
SAMPLE C vs POLYPROPYLENE
TEST | SAMPLE C | POLYPROPYLENE | CHANGES IN (%) |
TENSILE (N/mm2) | 96.45 | 35 | 275.5 % |
FLEXURAL (N/mm2) | 162 | 50 | 324 % |
HARDNESS (N/mm2) | 99 | 82 | 120.7 % |
From these result we can say that Sample C gives twice the result of polypropylene.
COST ESTIMATION
Description | Cost in Rs. |
Material Purchase( Carbon Fibre, Basalt Fibre, Epoxy, Hardener, PP sheet) | 6,772 |
Composite Material Fabrication and Std. Specimen preparation | 7,000 |
Mechanical testing ( Tensile, Flexural, Hardness) | 2,600 |
Scanning Electron Microscopy | 3,600 |
Thermal gravimetric Analysis | 3,900 |
Miscellaneous | 3,000 |
Total | 26,872 |
CONCLUSION
REFERANCES
1. Abada et al., made a reviewon “Safety focused modeling of lithium-ion batteries: A review”, Journal of Power Sources Volume 306, 29 February 2016, PP 178-192.
2. Aikun Tang et al., published a research paper at (2019) on “Optimization design and numerical study on water cooling structure for power lithium battery pack. Applied Thermal Engineering Volume 159, August 2019, 113760.
3. M. Alipour, E. Esan, and R. Kizilel published a research paper at (2019) on “Investigation of 3-D multilayer approach in predicting the thermal behaviour of 20 Ah Li-ion cells”, Applied Thermal Engineering Volume 153, 5 May 2019, Pages 620-632.
4. Daniel R. Wright et al., published a paper at (2018) on “Review on high temperature secondary Li-ion batteries”, Energy Procedia Volume 151, October 2018, Pages 174-181.
. 5. Huaqiang Liu et al., published a paper at (2017) on “Thermal issues about Li-ion batteries and recent progress in battery thermal management systems: A review”, Energy Conversion and Management Volume 150, 15 October 2017, Pages 304-330.
6. Jaewan Kim et al., made a review on (2019) at “Review on battery thermal management system for electric vehicles”, Applied Thermal Engineering Volume 149, 25 February 2019, Pages 192-212.
7. Jiwen Cen, Zhibin Li, Fangming Jiang published a paper on (2018) at “Experimental investigation on using the electric vehicle air conditioning system for lithium-ion battery thermal management”, Energy for Sustainable Development Volume 45, August 2018, Pages 88-95.
8. Kai Chen et al., made a research on (2019) at “Cooling efficiency improvement of air-cooled battery thermal management system through designing the flow pattern”, Energy Volume 167, 15 January 2019, Pages 781-790.
9. Leire Martín-Martín et al., published a paper on (2018) at “Optimization of thermal management systems for vertical elevation applications powered by lithium-ion batteries”, Applied Thermal Engineering Volume 147, 25 January 2019, Pages 155-166.
10. Y. Lyu et al., (2019) “Electric vehicle battery thermal management system with thermoelectric cooling”, Energy Reports Volume 5, November 2019, Pages 822-827.
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