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May or may not have 2 different materials for each section as the rear section has two supports.
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Fiberglass
Typical thickness for fiberglass covers is around 1/8 to 1/2 inch (3.175mm - 12.7mm).
Fire resistant resin available.
Rough estimate of 6.3m^2 of battery cover.
https://compositescanada.com/fabrics/
https://www.youtube.com/user/easycompositestv/videos
Canadian site for composite materials, including fiberglass cloths: https://www.rayplex.ca/page328.html
Thickness of 9oz cloth: 0.28mm. To achieve a thickness of 1/8 inch would depend on layers of fiberglass and applied resin (need more research).
Fiberglass Sandwich (Foam core)
A foam core with fiberglass on either side adds stiffness and strength while keeping the piece itself relatively light. When a foam core is used to double the thickness of a structure, the relative strength can go up by 7 times while barely increasing the overall weight.
The foam core in addition to the fiberglass skin forms compressive and tensile properties on either sides. Which is why adding a core of any kind increases strength.
Some resins melt foam, need to find a resin that does not melt foam and is also fire resistant.
Resin
Epoxy resin will be used.
Note: sandwich fiberglass composite
Polyester resin melt foam, so most likely an epoxy resin would be used.
Material Concepting
Pros | Cons | |
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Fiberglass |
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Wood |
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Carbon fiber |
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Plastic (not sure which yet) |
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Concepts for what manufacturing processes to use
3D Printing | Useful for prototyping or proof of concept testing |
Vacuum Forming | Thermoforming where sheets of plastic can be formed into objects such as covers |
Mold shaped into battery cover where it could be used to create a fiberglass cover |
Mold
Useful info: https://www.rayplex.ca/mouldingfibreglass.html
Most likely be using a male mold for the cover.
Assembly Concepting
Concepts for how various materials and parts will assembly together
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