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Why are EV battery enclosures made out of aluminum?

Suppliers of composites and plastics are undeterred by aluminum’s current dominance in EV battery enclosures. They’re developing new formulations and processes aimed at matching or exceeding the performance and cost-competitiveness of the light metal. “Current battery packs use a lot of metal that is not optimized.

What is an EV battery enclosure?

(Novelis) EV battery enclosures are a hotbed of subsystem design, materials innovation, and vehicle integration. The importance of supporting and protecting the EV battery has kicked off a new wave of creativity among engineers and materials scientists.”

Are aluminum battery enclosures a good choice?

Aluminum battery enclosures typically deliver a weight savings of 40% compared to an equivalent steel design. According to Asfeth, the alloys best suited for battery enclosures are the 6000-series Al-Si-Mg-Cu family — alloys that are also highly compatible with end-of-life recycling, he said.

Are thermoplastics better than aluminum for EV battery boxes?

Two more characteristics make thermoplastics competitive with aluminum for EV battery boxes, Nagwanshi said. One is their anisotropic thermal conductivity — plastics’ ability to simultaneously conduct/dissipate heat in one direction, while providing insulation in other directions.

Who makes EV battery box covers?

CSP is North America’s largest manufacturer and molder of composite materials. The company has produced more than 30 different composite battery-box covers for EVs in China and North America, including the Chevrolet Spark EV. The move from supplying battery box covers to fully assembled, multi-material battery enclosures is in full swing.

What are thermoplastic EV battery trays?

Engineers’ interest in thermoplastic EV battery trays began with GM’s 1990 Impact concept car. The EV-1 production car that followed used a tray made of glass-filled polypropylene (PP). SABIC’s latest innovation aims directly at one of aluminum’s weaknesses — its very high thermal conductivity.

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In the composites world, the relatively lighter weight, higher strength and thermal resistance properties of many composite materials make them an increasingly attractive alternative to metal for EV battery covers in …

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