Aluminum Extrusions For Electric Vehicle Battery Tray

The weight of the EV battery tray can vary a lot because of many factors. These include the capacity of the battery, the type of car, and type of battery material. Some enclosures are as light as 40kg while some weigh over 150kg.

Yes, there are standards and regulations for EV battery box manufacture. As the rush for EV vehicles continues, the need for safety and other product aspects is huge. Regulations and standards mostly touch on both environmental and human safety. At FONNOV, we adhere to national and international requirements for EV vehicle component manufacture.

Composites are a viable alternative to aluminum extrusion for EV battery pack enclosures. Apart from having been in the automotive industry for a long time, composites are light and easy to fabricate. They are preferred by some electric vehicle battery tray manufacturers for the top lids of enclosures. At the moment, this material is not yet mainstream for not only its higher cost but also approval and manufacturing challenges.

Aluminum extrusion for electric vehicle battery tray beats steel in one main area – weight. A steel battery tray can be 50% heavier than one made from aluminum. The relative energy efficiency offered by aluminum is therefore significant. It means a lot for EV battery manufacturers, particularly those interested in increasing the size of power packs.

When designing the EV battery trays, you need to consider the following factors:

• Thermal runaway from the battery
• Corrosion resistance of the tray material
• Weight of the tray
• Size of the tray
• The impact of car movements, crashes, etc.
• Heat generated from the car

FONNOV EV battery trays are made from the best aluminum alloys in terms of impact resistance, corrosion resistance, and strength. Making the enclosure from aluminum is also very effective in warding off electromagnetic interference that may affect sensitive car components.

Our main alloys for EV battery trays are aluminum 6061T6. This material has excellent characteristics for the optimal performance of the EV battery tray. For instance, 6061 extruded aluminum is light, moderately strong, and corrosion-resistant. It is also formable and has good thermal conductivity. The material dissipates heat excellently, thus enhancing the safety of the battery.

Building the EV battery tray is a systematic process that involves different manufacturing processes. CNC machining is a popular one, given its dynamism and dimensional accuracy. Manufacturers can achieve most of the project requirements using this process. With the popularity of aluminum in this industry, aluminum extrusion is an equally common process. The most complex trays can be made using extrusion. To satisfy the high demand for enclosures, the manufacturer may opt to use the injection molding method, which also allows for sophisticated geometries.

While aluminum extrusions remain the mainstream choice for electric vehicle battery enclosures, other materials are available in the market. Stainless steel offers good machinability, superior strength, and sturdiness. Heat resistance is one of the biggest advantages of stainless steel for EV battery trays. Other manufacturers use fiber composites, mostly for rigidity and low weight. The material can also resist fire. Thermoplastics are also usable in the manufacture of EV battery enclosures. Other than being cost-effective, these materials are strong.

EV batteries comprise many components and can be extremely heavy. Weight saving is one of the priorities when designing the tray. Our aluminum extrusions are strong and lightweight, hence can solve the low weight requirement. The low weight is critical in your fuel management goals.

Further, aluminum extrusions with a custom designed shape are safer for the EV battery tray and the battery itself. Experts have approved the aluminum extrusions for excellent performance in tough environments and energy absorption in case of a crash.

Even without a collision, the typical vehicle subjects its components to a lot of harsh conditions every day. The EV battery is at risk of serious impacts. In case of a crash, it can even spill its contents. The main solution to safeguard the battery is to make the tray impact-resistant through a ruggedized tray design. When well executed, this method ensures that road roughness, impacts, and normal vehicle vibrations do not damage the tray and the battery.

Yes, custom aluminum extrusions with their unique design offer many benefits that encompass crash impact absorption, high strength-to-weight ratio, and the passage of fluids through the structure without leaking.

The electric vehicle battery tray holds the battery pack firmly. Second, it ensures that fluids from the battery don’t pollute the environment in the event of a vehicle crash.