Lighter and safer: an aluminium-foam battery case
The company Havel metal foam GmbH has developed a battery box that is not only lighter than conventional battery cases. It also provides improved protection for the battery.
The challenge when constructing electric vehicles is to reduce deadweight using lightweight design and thus increase the vehicle’s range. Now, the company Havel metal foam GmbH has developed a battery box that is not just lighter than conventional battery cases. It also provides improved protection for the battery.
The battery casing in an electric car must fulfil several requirements: The material must be high strength and, as batteries are usually built into vehicle floors, the construction as a whole must have a good crash behaviour. Even just an impact on the undercarriage can damage the battery. The casing should also facilitate temperature regulation because the performance of lithium ion batteries decreases in frosty conditions and the battery ages faster at temperatures above 30 degrees. Most importantly, the battery casing should be very light in order to minimise the effect on the vehicle’s range.
Havel metal foam GmbH from Brandenburg an der Havel has now, with the assistance of lightweight design technology, developed a battery box that better fulfils these requirements than conventional battery cases. The company won the Brandenburg Innovation Award for Metal 2019 for this innovation.
Safety soon in series production?
Pipes for regulating temperature are welded into conventional battery cases. However, welding seams are a potential weak spot because they can break. Havel metal foam GmbH has found a solution that avoids welding. Stainless steel pipes are placed in the aluminium foam. Together they form a direct metallurgic bond. This method is also more economic, as additional welding work by man or machine is not required.
The aluminium foam battery box is suitable for all vehicle sizes. The Brandenburg company is already negotiating with various vehicle manufacturers so they can mass produce their innovative battery case.
Safety soon in series production?
Pipes for regulating temperature are welded into conventional battery cases. However, welding seams are a potential weak spot because they can break. Havel metal foam GmbH has found a solution that avoids welding. Stainless steel pipes are placed in the aluminium foam. Together they form a direct metallurgic bond. This method is also more economic, as additional welding work by man or machine is not required.
The aluminium foam battery box is suitable for all vehicle sizes. The Brandenburg company is already negotiating with various vehicle manufacturers so they can mass produce their innovative battery case.