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LeiBat - Lightweight battery housing

Development and production of a recycling-friendly lightweight hybrid battery housing

 

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Leibat FLB

Project: Development and production of a recyclable lightweight hybrid battery housing

LeiBat - Lightweight battery housing

 

Challenge and objective The current BEV market requires significant cost reductions and range increases, especially in the small car segment. The project addresses these needs by developing a generic, recyclable steel-plastic hybrid battery housing (BG). The aim is to achieve a weight reduction of 30-40% and a CO2 reduction of over 65% in production compared to pure steel housings. The aim is to raise the maturity level of the technology from TRL 3-4 to TRL 6-7.

Technological innovation The focus is on a new type of hybrid construction made from edge-formed sheet steel and glass fiber-reinforced polypropylene (PP-GF40). By dispensing with energy-intensive deep-drawing processes and the use of extrusion presses, production costs are massively reduced.

The core scientific achievement lies in the reliable control of the plastic flow:

  • Integrated sealing: special process control enables FRP clinching to seal open corner areas and creates a form-fit connection without adhesion promoters - a basic requirement for the circular economy.
  • Extrusion molding on both sides: The innovative insertion of plasticizers on both sides of the steel inlay guarantees complete enclosure and the formation of complex ribbed structures.
  • Functional integration: Filigree, energy-absorbing honeycomb structures and space-optimized cooling circuits for LFP blade and round cells are directly integrated.

Economic relevance The substitution of CO2-intensive cathodic dip-paint coatings with uncoated profiles and the realization of tight tolerances using moldflow simulations enable near-series production. The project strengthens the technological leadership of European industry and reduces dependence on global supply chains through highly efficient, locally producible lightweight solutions.

Overview

  • Icon Kalender

    Duration
    01.01.2026 - 31.12.2028 (ongoing)

  • Icon Tag

    Research field
    Battery electric vehicles

  • Icon Abzeichen Euro

    Funding
    EFRE - NRW 2021/27 - Innovation competition Industrie.IN.NRW

Relevant links

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Overview of the work packages in LeiBat

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WP1: Definition of installation space and material concept

  • Installation space definition: Definition based on CAD data of the reference vehicle (small car segment/Ford Fiesta).

  • Integration: Synergetic integration of the battery housing into the existing vehicle structure.

  • Restrictions: Strict adherence to geometric and functional framework conditions.

  • Choice of material: Selection is based on legal requirements and market demands.

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AP2: Mini battery housing

  • Scaling: Development of a 1:4 housing, but with 1:1 structural features to ensure the transferability of the results.

  • Test setup: Use of a modular tool for testing inlays, flow and function integration.

  • Process optimization: use of moldflow simulations and analysis (pressure/temperature) for ideal mold filling.

  • Quality objectives: Minimization of component distortion and obtaining valid material samples for subsequent series production.

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WP3: Material characterization and testing

  • Material testing: Characterization of hybrid materials (steel QP1180/plastic) using high-speed tensile tests for precise crash material maps.

  • Validation: Verification of joint strength and deformation behavior using shear tensile and impactor tests.

  • Structural analysis: Special focus on the behavior of rib structures under load.

  • Quality comparison: Optimization of manufacturing tolerances by comparing 3D measurement data with the simulation.

  • Objective: Minimization of component distortion to ensure high housing quality

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WP4: Design of the battery housing and the hybrid crash profiles

  • Design strategy: Focus on the virtual design of the hybrid housing using topology optimization and FEM simulations (1:1 scale).

  • Efficiency target: Realization of a massive weight saving of up to 40%.

  • Crash validation: Carrying out numerical crash simulations in the overall vehicle model.

  • Optimization loops: Finalization of the design through iterative parameter variation (e.g. material combinations such as PP-GF40 and QP1180).

  • Project result: Creation of a production-ready CAD model that takes all process-related restrictions into account.

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WP5: Design of thermal management for the different cell types

  • Thermal strategy: Use of CFD simulations to control extreme temperatures(-40 °C to +60 °C).

  • Geometric optimization: fine-tuning of extruded aluminium profiles (adjustment of channel cross-sections and number of chambers).

  • Performance maximization: The aim is to maximize heat transfer while minimizing pressure loss.

  • System benefits: * Process-safe thermal conditioning.

    • Increased cell service life.

    • Increased safety in high-performance load cases (high performance)

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WP6: Development of space-saving media connection and intensive temperature control

  • Connection technology: Use of the MPDB® process for a media-tight and space-saving connection of the cooling structures.

  • Cell flexibility: Development of optimized concepts for different cell formats(blade, round and LFP cells).

  • Space optimization: Focus on particularly flat geometries to minimize the required volume.

  • Flow design: Strict adherence to technical parameters to ensure efficient flow.

  • Validation: Validation through functional demonstrators as well as targeted leak and load tests for real operation.

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WP7: Development and production of tools

  • Modular tool systems: Use of a segment design to flexibly vary and test rib structures and wall thicknesses.

  • Hybrid crash carriers: Development of a specific tool for the production of hybrid components.

  • Magnet technology: Use of magnets for precise fixing of steel profiles during the process.

  • Honeycomb structures: Safeguarding mold filling for complex geometries through targeted simulations.

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Ap8: Development of automated handling and demonstrator production

  • Ramp-up & cycle time: Scaling to robot-supported production with a target cycle time of less than 70 seconds.

  • Plant technology: Use of a 3000-ton press to manufacture the hybrid components.

  • Assembly process: Multi-stage assembly consisting of cooling systems, battery cells and the base plate.

  • Validation: Creation of a functional overall system as proof of the suitability of the lightweight innovations for large-scale production.

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WP9: Testing and quality assurance

  • Physical validation: Assurance of component quality through 3D scans, micrographs and real crash tests (in accordance with NCAP standards and drop tower tests).

  • Energy management: Use of load cells for precise verification of energy absorption in the rib structures.

  • Cell safety: Validation of cell integrity under mechanical load.

  • Knowledge transfer: Creation of a standardized development guideline as a strategic guideline.

  • Series focus: Ensuring the transition from research to industrial series development in the areas of material selection, design and production.

Financing

 

Innovationswettbewerb Industrie.in.NRW LAND NRW, EU

The project is funded by the ERDF program Innovation Competition - Industrie.IN.NRW.

Co-financed by the European Union.

 

Relevant links:

 

ERDF Program