Case Study: Why are Engineering Plastics the Superior Material for HV Battery Enclosures?

When it comes to the heart of a car – the enclosure of the high voltage battery system – the designers typically consider metallic materials only. During the last three years, Envalior has proven the feasibility of a thermoplastic battery tray and cover. Based on series processes several hundred prototype parts were molded, equipped with the necessary components and tested. The design verification plan consisted of e.g. thermal runaway tests, leakage tests and crush tests. As a final result, a car with such a prototype enclosure received the certification of the TÜV and drives for several thousand kilometers on the road. The presentation will give you insights, how the part was designed, how much savings in terms of cost and weight could be achieved and last but not least, the carbon footprint of Aluminum und plastics are being compared.

Julian Haspel

Head of e-Powertrain Team, Envalior GmbH