Battery Cases for Electric Cars

Components made from carbon fiber-reinforced plastic (CFRP) and glass fiber reinforced plastic (GFRP) have excellent mechanical properties, such as high stiffness and strength combined with low weight. For example, a battery case made from CFRP can save up to 40 percent weight compared to aluminum or steel. In addition, our composite components ensure improved fire protection, underbody protection and optimum temperature conditions within the battery. Outstanding safety for electric vehicles that can save lives.

An e-vehicle that is 100 kilograms lighter saves around four percent of driving energy, as studies by the engineering service provider EDAG and the Fraunhofer Institute for Chemical Technologies (ICT) show. Lightweight construction thus significantly helps to increase the range. Alternatively, a lower weight with the same range allows the installation of smaller and lighter batteries, which again saves costs, reduces installation space and shortens charging times. Scientists at Munich University of Applied Sciences, for example, assume that such downsizing in the order of 100 kilograms of weight savings will lead to a reduction in battery costs of up to five percent. In addition, lower weight supports driving dynamics and reduces dimensioning and wear in brakes and chassis. Composite materials also exhibit particularly high stiffness and thus contribute to increased crash safety.

The thermal conductivity of fiber composite, which is about 200 times lower than that of aluminum, is a good prerequisite for effective protection against fire in the battery of electric cars, which can be further improved by additives. For example, our internal tests show that composite materials, even without mica, last up to four times longer than steel. This gives occupants valuable time for rescue in an emergency.

Due to the low thermal conductivity of the composite materials, the material also contributes significantly to optimized thermal management. The battery is automatically better shielded against heat and cold by the housing material. With the appropriate design, there is even no need for additional insulation.

Fiber composite materials do not have to be provided with an additional corrosion layer, as it is in the case with steel. These materials are not susceptible to rust, and even if the underbody is damaged, the structural integrity wouldn’t allow for any leaks.

The underbody and lid are flat components that can be produced in large quantities with consistent quality in a material-efficient manner. However, the frame structure can also be made from composite material using new manufacturing processes. possible

In a total cost analysis, battery cases made of composite material can even achieve a cost level similar to aluminum and steel in the future due to the many advantages.

In addition, our materials meet other requirements for battery housings, such as electromagnetic compatibility (EMC), water and gas tightness.

We manufacture our battery cases from carbon and glass fiber textiles – according to customer requirements. The excellent properties of the fiber composite construction make the battery enclosure a supporting element of the vehicle structure. We accompany you in all stages of your product development: from planning and conception to product completion and serial production in automotive quality and high volumes – and all this at attractive costs. Call us or write to us, we look forward to an exciting project with you.

Also read:

Why Lightweight Construction and Electromobility Belong Together