The battery enclosures used in the first wave of EVs to hit the market after 2010 were designed to be sealed firmly shut. This took to an extreme the need to be impenetrable, crash proof, fireproof, waterproof and tamper-proof and resulted in mostly irreparable batteries and recycling processes that frequently require people in protective clothing using crow bars to prise open the enclosures protecting these very heavy, high-voltage machines. But technologies and production strategies are fast-evolving.
Critical for contemporary battery enclosure strategy is design for disassembly, fire and thermal runaway protection, crash performance and recyclability. But the EV battery market is evolving fast, with frequent changes in battery chemistries, battery formats (pouch, cylindrical, prismatic) and battery technologies, with the arrival of solid-state battery technology drawing ever closer. And all of these have implications for the EV battery enclosure.
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