Development of Sustainable Aluminium Foam Components Infiltrated with Paraffin for Battery Housings

Improved sustainability of car components like battery housings can be achieved using lightweight designs and infiltrated aluminium foam, providing high mechanical energy absorption and damping properties. Furthermore, their mechanical properties as well as the thermal conductivity and resistivity are much higher than those of polymer foams. Investigations were carried out on structures containing paraffin, a phase change material, infiltrated into the highly thermally conductive aluminium foam. Unique manufacturing processes and infiltration methods were developed and tested. The state-of-the-art for infiltration of aluminium foam with paraffin was extended by two infiltration methods, enabling higher infiltration rates, increasing the effective thermal conductivity. Simulations regarding heat distribution and vibration properties were performed and validated by experimental investigations on the component level. Variation of properties for multi-functional components can be designed through foam density and paraffin. The sustainable composite solution, with recyclable aluminum and ecologically harmless, non-corrosive paraffin, is recommended for applications requiring both mechanical and thermal beneficial properties, such as battery housing floor components.