The design of an enclosure or container for the battery revolves around two things: adequate selection of materials and design for adequate heat transfer. The most preferred battery enclosures are fabricated using plastic materials that are resistant to alkaline solutions and come with a high impact strength.Metal housings are also used at certain times, however, metal needs meticulous design and assembly to avert shorting of the cells in the battery pack. Aluminum is never recommended for battery enclosures since if cell leakage happens the electrolyte would react with the aluminum.
Custom Design and Excellent Battery Form Factor
The custom battery enclosure may furthermore have a big impact on battery life if not designed adequately to avoid the cell’s temperature from rising considerably in overcharge. Excellent battery form factor enables air movement around cells to help decrease temperature rise in overcharge.
Importance of Enclosure Protection Venting
Battery enclosures are basically sealed metal or plastic shells designed to give battery protection from dust, debris, and moisture, for example, rain, snow, and car-wash sprays. Any one of those elements is likely to damage battery cells and ancillary electronics. Hence, a custom-designed enclosure keeps those possible harmful materials away from the battery. A battery pack for an electric vehicle could have hundreds of cells housed inside many modules.
Apart from keeping contaminants at bay, battery enclosures have to deal with pressure differentials between the enclosure interior and the encompassing atmosphere. The pressure differential could fluctuate drastically during normal vehicle operation because of ambient temperature variations, heat generation in cells, and atmospheric pressure variations. Same as an automobile passenger usually experience “ear-popping” when navigating mountainous terrain, battery enclosures experience similar pressure fluctuation as elevation changes.
Venting BalancesInternal and External Pressures
To avoid the collapse of the protective shell, enclosures need to be vented to balance internal and external pressures, while releasing gases generated in a rapid pressure buildup, also known as “thermal runaway.” Whether steady or abrupt, pressure buildup could stress seals, resulting in leaks and potential explosions.
The exact effects of venting may be better figured out by inspecting the interior of a lithium-ion automotive battery. A battery pack typically comprises two sections fastened together, with a gasket sealing the connection. If the custom battery enclosure is not vented adequately, leaks can develop following the enclosure experiencing multiple minor pressure differences. With electric automobile manufacturers at times offering eight-year warranties, battery enclosures are expected to last that long at the most. Proper venting decreases the number and severity of pressure differentials experienced by the seals, increasing the life expectancy of the seals and enclosure itself. vdcasino
Key Guidelines For Battery Environments
For extremely hot climate:
- Avoid direct sunlight on the custom battery enclosure, via a shade if needed.
- Prefer light-colored enclosures in every case.
- Let plenty of air circulation through adequate air space and ventilation.
- Avoid the use of a heavily insulated enclosure; this retains internal heating.
- Do not fear the use of an “oversize” shelter. This will let more air volume inside and have a greater surface area for heat losses.
For extremely cold climate:
- Reverse the above guidelines, however, be wary of summer temperatures.
- Use a thoroughly insulated enclosure.
- Use minimal air space around the battery; however, avoid restricting needed ventilation.
- Use whatever heat source is available (for instance waste heat from a backup generator); could consider using passive solar techniques.
Nutshell
The battery enclosure must be custom designed with adequate ventilation to avoid an accumulation of explosive gases. Custom-designed venting systems help fend off contaminants along with pressure equalization during normal operating conditions, so extending the enclosure life and battery life cycle.
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