Electric Vehicle Battery Enclosure

This composite EV battery enclosure was required to meet a number of severe performance requirements, including 30o offset-barrier, side-impact, and rear-barrier crash; 50 G impulse shock (x, y, z); post-crash package integrity; fire-resistance testing; 3-m drop testing (bottom/end); 1-m water-submersion test; and vibration/shock testing. To satisfy all criteria, a new material, production process, post-mold finishing, and non-destructive test methods were needed. The result is industry's first application of a VOC-free thermoset vinyl ester resin reinforced with a coarse basket-weave glass rove cloth to form a complex-shaped enclosure that protects the EV's battery components in the event of a catastrophic event.  The tough compression-molded composite is 40% lighter than metallic solutions, helping the vehicle achieve extended range and enhanced performance.  Since it is non-conductive, it protects occupants and first responders to an accident scene. Specially formulated resin is free of styrene emissions, making it safer for workers and the environment. Selective pattern layups allow for localized reinforcement. The application also features a large structural joint of composite to steel.

OEM/Vehicle General Motors Co. 2014 Chevrolet Spark EV System Supplier A123 Systems, LLC Material Processor Continental Structural Plastics

Material Supplier Cytec Industries Inc. Resin Vinyl Ester Tooling/Equipment Supplier Century Tool & Gage

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