High Temperature Composites for Next-Generation Fire-Resistant Battery Boxes

To meet the UK's 2050 net-zero emissions target, the sale of new petrol and diesel passenger vehicles are to be banned from 2030, so manufacturers are rapidly developing batteries for electric and hybrid powertrains. However, metallic battery enclosures are heavy which reduces vehicle performance and range, while current composite materials struggle to meet the stringent fire, structural and cost requirements.

Battery boxes are normally manufactured from aluminium, with some being steel or composite materials. Fire-resistant epoxy, PFA and some thermoplastic composites can meet current demands of structural performance and fire protection, but none of these materials is expected to meet the emerging fire performance standards alongside high mechanical properties and low cost.

The objective of this project is therefore to develop a new family of composite battery enclosures that meet these demanding requirements.

To prove the concept, the key project output will be a prototype enclosure and 10kWh representative section of a battery pack, tested to relevant standards.