Battery Casing Products and Services

With our market and technology know-how, simulation methods, cost and CO₂ footprint analysis and testing capacities, we provide consulting and development for your materials, products and technologies.

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Emerging Battery Storage Technologies

AZL Joint Partner Project | Open to Join

Insights into emerging battery storage technologies and their impact on design factors for battery casings

Do you know…

… that the global battery market is set to grow by 34% annually until 2030? In the race for market share, new players are catching up.
… that battery technologies, like solid-state not only have the potential of surpassing energy density compared to conventional LIBs, but also offer increased safety?
… what are the material and design options for battery housings for cells with nonthermal propagation cell technologies?

What you’ll get:

Expert assesment and evaluation of future battery technologies and their impact on requirements for material and design of battery casings.

WP1: Screening of future battery technologies and trends with high market potential
WP2: Impact analysis on future battery housing requirements, materials and design layouts
WP3: Creation of design layouts and analysis of material variants.
WP4: Business case scenarios for future design- and manufacturing concepts.

Thermal Propagation in BEV Battery Casings

AZL Joint Partner Project | Open to Join

Techniques for prediction of cell- and caasing behaviour after the initial trigger event for thermal propagation

Do you know…

… what happens at a thermal runaway event for different battery cell chemistries? Will a flame result? What temperatures will occur?
… how will the hot released gasses spread through the battery pack and put thermal and mechanical
… how to predict whether a battery pack will safely survive a thermal runaway event according to regulations?
… how effective different shielding materials avoid thermal propagation?

What you’ll get:

The project provides know-how and predictive methods for the events happening after a first thermal runaway of a battery cell.

WP1: Analysis of state of the art and future battery cell types.
WP2: Analysis of thermal runaway cell to cell propagation behaviour for different cell types
WP3: Analysis of hot gas development and flow through the battery pack, pressure build-up and temperature loading on the battery casing structure.
WP4: Example thermo-mechanical CAE analysis for different tray and lid layouts, using different materials.

Application Relevant Fire Test Procedure for Battery Pack Protection

AZL Engineering Service

Material Strength Test

3 different temperatures: 800°C, 1000°C, 1200°C
During exposure to fire: tensile force of 0.5 kN over 10 minutes
If no failure, increase force up to 5 kN

Particle Blast Test

Equal damage effect of thermal runaway with real battery cell
Exposure to 1200°C for 80 seconds
Afterwards 10 seconds blast duration, filling mass 450 g

Test specimen size for both tests is 200 mm x 100 mm, flame exposure along the full specimen width Approx. 10 test specimens required, 2 for each tests and temperature

AZL’s Expertise

AZL Joint Partner Project completed in 2022:

Fire Protection – Application Relevant Fire Test Procedure for Composites

Consortium of 24 industrial partners along the complete value chain
Setup of test procedure and test bench with 3 different temperatures measuring the material strength under fire load
50+ materials tested and compared
Impact on performance, weight and cost

To learn more about fire safety for electric vehicles, watch the Clariant & AZL webinar on SpecialChem: The Material Selection Platform:

“Safeguarding Electric Vehicles: Fire safety solutions for HV connectors and battery enclosures”

Fill out the form below to get free access.

Application Relevant Bottom Impact Protection for Battery Casing

AZL Engineering Service

Simulates oblique angle impact occurring in high-speed driving over hard objects
3 different angles for impact possible: 90°, 45° and 25°
15 mm dart impactor, max. height 4 m, max. mass 60 kg
Large-scale tests and small-scale tests (only 90°)

Test specimen size for large-scale 400 mm x 400 mm, small-scale 120 mm x 120 mm. Approx. 2 specimens for each angle in large-scale test, 10 specimens for small-scale test.

AZL’s Expertise

AZL Joint Partner Project completed in 2022:

Application-relevant test method and investigation of the relative safety performance of different material options for bottom impact protection battery casings

Consortium of 13 industrial partners along the complete value chain
Improvement of an existing test bench* for 25° oblique impact and setup of test procedure
20+ materials tested and compared
Impact on performance, weight and cost

*Original test bench developed by Thyssenkrupp

EV Battery Casings Consultancy

AZL Engineering Service

Together we analyse the fast-growing market for EV battery casings and identify opportunities for your materials, products and technologies considerung cost, weight and environmental impact

Our Assets related to Battery Casings

AZL conducted several consortium projects with 76 industrial companies along the complete value chain, investigating:

Worldwide standards, regulations and specifications
60+ state of the art casings and future concepts
About 30 different multi-material design concepts, including future cell-to-pack designs
- Alternative cell-packing and cooling options for future cell-to-pack designs
- Analysis of Alternative materials to mitigate thermal runaway propagation
- Analysis of and design for recycling
CEA analysis and optimisation to crash and intrsuion load cases
Modelling production chains and benchmarking analysis of weight, cost and CO2 footprint, and volumentric efficiency
Experimental testing of high speed oblique foreign object impact protection, more than 25 different materials
CAE design relevant fire safety testing, more than 50 different materials and protection layers

Whitepaper "Opportunities for composite material in future multi-material battery enclosures"

Download Whitepaper

“Opportunities for composite material in future multi-material battery enclosures”