SHAPE FORMING
BOXING CLEVER
Considering aluminium or steel for your electric vehicle’s battery enclosure? How about a composite instead?
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n the United States, the Environmental Protection Agency (EPA) says that for every 100 pounds (45kg) of
weight taken out of a vehicle, the fuel economy is increased by 1-2%. Let’s consider how composite EV battery enclosures could support the overall lightweighting mission, and provide additional structural benefi ts compared with the traditional metal off erings. Battery enclosures for EVs, also called frames, boxes or housings, have the primary purpose of holding and protecting the battery cells. They come in diff erent shapes and sizes, and much like other vehicle parts, are an arena for several materials fi ghting for prominence. Aluminium and steel
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are traditional material choices. Yet, composites could provide an improved alternative, which will signifi cantly improve the performance of the EVs.
THE HURDLES AHEAD Mass EV adoption is currently held back by range anxiety — concerns that vehicles won’t be able to travel far enough on a single charge. To alleviate this, there is an unquestionable need for safe, lightweight and cost- eff ective EVs. For these EVs to make it in the market, the components that form them must also possess these qualities. If a part can be made using a lighter material without compromising safety and function, then it’s a no-brainer for designers
and material selectors in original equipment manufacturer and system supplier businesses. In some instances, switching from metal to composite doesn’t just match previous functionality, it surpasses it by bringing in additional benefi ts. This is demonstrated in the case of EV battery enclosures, as composites off er weight reduction, improved insulation, reduced noise, vibration and harshness. Let’s look closer at each characteristic.
WEIGHT REDUCTION This is arguably the main driver in choosing composites, as a weight saving of up to 40% can be achieved if the enclosure is made from a pure
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