EAC+

Sustainable Electric Architecture Casings

The aim of EAC+ was to develop recyclable economically and technically competitive casing structures that have a high potential to be used in a wide range of industries and at the same time meet the high electromagnetic requirements of electromobility. The casing structure was realized as a hybrid component in which a thin metal sheet provides the electromagnetic compatibility (EMC) and the thermoplastic component transfers the mechanical loads. Such casings are intended for use in a wide range of industries, from mobility to renewable energy technology.

A new type of hybrid injection moulding was developed with the EAC+ project partners. This combines injection moulding and metal forming in a single process. The innovation of the EAC+ technology is based on the new design and the unique process. These enable the production of highly integrative, low-CO2 and recyclable products that are lighter and more cost-effective than today's solutions while meeting the high requirements for EMC. In order to objectively evaluate and prove the sustainability of these innovations, a life cycle analysis was carried out, which enables a holistic assessment of the environmental impact from raw material to recycling. Several demonstrators of varying sizes and complexity were developed as part of the project. For example, a demonstrator structure consisting of a casing half, in which a prototypical power electronics was mounted, was successfully manufactured and tested (see fig.).