Automotive Engineering - April 2021 - 9

TECHNOLOGY REPORT

CONSTELLIUM

Enclosure design

The battery enclosure has a critical role
in crash energy management, both in
terms of preventing intrusion into the
battery cells as well as absorbing energy
to protect the passengers. A dual-frame
prototype illustrated by Constellium employs two different advanced extruded
alloys. The inner frame is made of
strength-optimized 6000 from the HSA6
family, while the outer reinforcement is a
ductile 6000 alloy of the HCA6 family.
" The inner frame's main function is to
prevent intrusion into the cells even if it
leads to fracture of the metal, " he said.
" The outer reinforcement is designed to
crumple in a very controlled way without fracturing so the maximum amount
of energy is absorbed. "
The concept of placing battery cells
directly in the body-in-white (BIW) is
" very interesting " and would remove
the redundancy of having a " box within
a box, " he said. " If the trend continues

The current state-of-the-art solution for bottom plates is high-strength 6111 alloy in peak aged temper,
but still-in-development alloys promise even better performance and additional weight savings.
to eliminate the modules and then the
enclosures and have cells directly integrated in the BiW, effective sealing and
joining will grow in importance. "
If the industry shifts to solid-state batteries, the function of the enclosure likely
will shift, too. " We may see some loadbearing function in the solid-state battery
cells themselves and therefore less structural demand on the enclosure, " Afseth
said. Another trend he is seeing is OEMs

HV Connector

ICU

AUTOMOTIVE ENGINEERING

Built-in Cam

Thermal challenges

Despite lightweighting and recyclability
benefits, aluminum enclosures fare less
favorably when thermal runaway occurs

HV Junction
Block

(Integrated
Central control Unit)

HV/LV Wiring Harness

increasingly bringing the development of
battery enclosures in-house rather than
outsourcing to tier suppliers. " Most OEMs
and start-ups developing BEVs are at
least considering aluminum enclosures if
not actively developing them, " he said.

Battery Disconnect Unit

Free Info at http://info.hotims.com/79440-705

HV Charging
Coupler
B FA
(Busbar Frame Assembly)

April 2021 9


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Automotive Engineering - April 2021

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