As electric vehicles (EVs) are fast winning greater market shares, automakers seek new lightweight materials and design solutions. Working in close collaboration with engineering service provider EDAG Group, we have developed a unique solution for EV battery enclosures based on advanced thermoset and thermoplastic composite technology.
In the case that composite materials have not been recycled commercially on a large scale, aluminum alloy is still one of the best materials for the integrated environmental impact of the whole life cycle of the battery boxes.
(3) In the sensitivity analysis of driving mileage, the aluminum alloy box body is also the best choice for vehicle life. (4) Quantitative assessment using substitution factors measures the decrease in greenhouse gas emissions following the substitution of steel battery box with lightweight materials.
Therefore, reducing the environmental impacts of battery boxes can effectively enhance the environmental benefits of lithium-ion battery packs. Lightweighting, as one of the measures for energy saving and emission reduction in automobiles, is widely applied to automotive components such as seats 10, engine hoods 11, and fenders 12.
In the above study, a life cycle assessment of battery box made from three different materials was conducted to analyze their environmental impacts in practical applications. The results indicate that lightweight materials, such as aluminum alloy and CF-SMC, generally have lower environmental impacts compared to steel box.
Research on lightweighting in combination with battery boxes has also been conducted. Kaleg et al. 13 selected the 5052–0 series aluminum alloy as the material for the battery enclosure and, through finite element analysis, determined that a material thickness of 2 mm and a mass of 6.51 kg were the optimal design for the battery pack.
For the welding of steel battery packs, carbon dioxide gas shielded welding or resistance spot welding is commonly employed. Here, we take the former as an example and determine the electricity consumption based on the actual consumption of welding materials 25, which amounts to 0.0996 kWh.
As electric vehicles (EVs) are fast winning greater market shares, automakers seek new lightweight materials and design solutions. Working in close collaboration with engineering service provider EDAG Group, we have developed a unique solution for EV battery enclosures based on advanced thermoset and thermoplastic composite technology.
and low-cost box material for an electric car power battery.[3] In particular, the lightweight design of power battery box materials needs not only to reduce the weight, but also to fulfill the necessary criteria of vehicle strength and safety. For example, the ultra-light concept * Corresponding author: [email protected]
"The structural battery enclosure combines innovative materials and functional integration, resulting in a lightweight and cost-effective solution over the baseline metal design," said Kauffmann. "It represents a lower cost, …
Battery box lightweighting and stiffness are two important objectives of battery box design and improvement. In order to reduce a battery box'' s weight without
How lightweight materials are revolutionizing EV battery pack design, boosting energy density and performance. Dive into the details now!
design of power battery box materials needs not only to reduce the weight, but also to fulfill . the necessary criteria of vehicle strength and safety. For example, th e ultra-light concept ...
Most of the EV industry''s battery trays are made entirely of metal and can weigh more than 1,000 lb/454 kg including the batteries. CSP''s lightweight composite counterpart, reinforced with aluminum and steel, has advantages. "We can mold in attachments and sealing grooves and do unique design geometries to make it a leak-proof, sealed ...
The battery packs are crucial components of electric vehicles and may severely affect the continue voyage course and vehicle safety. Therefore, design optimization of the battery-pack enclosure (BPE) is critical for enhanced mechanical and crashwrothiness performances. In this study, a lightweight design of an automotive BPE under the loading …
As electric vehicles (EVs) are fast winning greater market shares, automakers seek new lightweight materials and design solutions. Working in close collaboration with engineering service provider EDAG Group, we have …
Analysis of steel power battery box. (a) Effective plastic strain, (b) Effective stress. 3.4 Comparison of structural design results of power battery box of different materials Table 4 tabulates figures of merit for power battery boxes made of various materials, as analysed above. The simulations reveal that the CFRP power battery box has the ...
Based on simulation results, the strength of battery packs made of three materials are compared under the same standard operating conditions, and the optimal option for lightweight power battery packs is thereafter obtained.
Al alloys are promising materials for lightweight battery box parts. The weight of the battery box can be reduced using the Al-Mg system as a replacement for the mild steel sheet [1]. Al-Mg alloys ...
3.Battery box part thickness analysis . 3.1 Thickness selection of the same stiffness . If the elastic modulus of a material is less than that of steel, it is necessary to take into
According to the ISO 14,044 standard, the Life Cycle Assessment (LCA) framework consists of four main parts: goal and scope ... Yunjiao Z, Jiqing C. Material selection and optimization of lightweight multi material power battery box. J. Jilin Univ. (Eng. Edn.) 2020; 50 (04):1227–1234. doi: 10.13229/j.cnki.jdxbgxb20190280 . [Google Scholar] 15. Li YM, Ha NN, …
By comparing the environmental impacts of the steel battery enclosure with those of lightweight materials such as aluminum alloy and CF-SMC composite material battery …
Lightweight battery enclosure design GANGULI Tanmay, DATE Prashant P. download PDF. Abstract: The battery box is the heaviest part of an electric vehicle and may account for 20-30 per cent of its weight. Therefore, the design of a lightweight battery box is an important step towards the lightweight design of the entire vehicle. In this paper, a ...
The purpose of the research is to improve the protection level of the battery pack to IP68, to optimize the sheet metal power battery box structure into a more lightweight frame structure,...
"The structural battery enclosure combines innovative materials and functional integration, resulting in a lightweight and cost-effective solution over the baseline metal design," said Kauffmann. "It represents a lower cost, lower weight and lower carbon footprint solution than the metal design."
This study focuses on comparing three battery boxes: a base case steel battery enclosure (1400 mm × 1200 mm × 200 mm), and two alternative lightweight materials: aluminum alloy and CF-SMC. The functional unit is defined as the entire battery enclosure, ensuring a quantitative assessment and comparability of carbon emissions throughout the ...
Aiming to the lightweight design of the battery box for electric vehicle, this paper research the design process and the strength analysis method of long carbon fiber reinforced thermoplastic (LCFT) for a
By comparing the environmental impacts of the steel battery enclosure with those of lightweight materials such as aluminum alloy and CF-SMC composite material battery boxes, this study...
Camco 55363 Standard Battery Box . Camco RV Standard Battery Box is a black lightweight, heavy-duty corrosion-resistant polypropylene box which is designed to secure and protect the battery. It includes lift-off lid, durable woven hold-down strap, foot clamps and stainless steel screws. This box meets USCG CFR 183.420 and ABYC E-010.7 ...
Based on simulation results, the strength of battery packs made of three materials are compared under the same standard operating conditions, and the optimal option for lightweight power …
Husqvarna Battery transportation box is a robust but lightweight and handy case for up to 4pcs of Husqvarna 36V batteries. UN3480 certified for safe transportation of lithium-ion batteries. Furthermore, the integrated inlet provides excellent thermal insulation and provides great shock absorption during transport. Ergonomic handles placed on ...
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