(Novelis) EV battery enclosures are a hotbed of subsystem design, materials innovation, and vehicle integration. Whether you call them packs, boxes, or trays, the structures that envelop and protect EV battery cells and their supporting electrical and thermal-management hardware are among the industry’s top subsystem priorities.
The “battle for the box” has kicked off a new wave of creativity among engineers and materials scientists. Roughly 80% of current EVs have an aluminum battery enclosure, but engineers are quick to note that the field is wide open for alternatives, based on vehicle type, duty cycles, volumes, and cost.
Tesla also has reduced the amount of aluminum in the battery enclosure for the Model 3 and Model Y compared to what was used in its S and X models. And public statements made by the company regarding the structural battery pack expected to come from Tesla’s Berlin plant indicate the upper and lower covers are steel.
SABIC currently produces a flame-resistant PP battery pack cover used by Honda in the China market. The cover eliminates thermal blankets, reducing weight by 40% vs. a similar metal cover. Next-generation thermoplastic battery pack and module prototypes are in development.
New Energy Ltd is a professional battery pack designer and manufacturer with more than 20 years of experience. We serve the industry in Europe and in the USA making innovative products with technology, enthusiasm and passion.
We guide the OEM customer in the selection of the most appropriate battery cell model based on the application needs. We focus mainly on Li-Ion based cell technology, including LiFePO4 and LTO solutions.
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