Magnesium as a Battery Enclosure Material

table comparing battery enclosure materials

Where the benchmark report asks how Estes Energy Magnus compares numerically to other packs, this one asks a narrower question: is magnesium actually the right enclosure material, on the physics and the evidence published so far. Magnus is used throughout as the worked example because it is the only near-production attempt at this scale; every … Read more

Magnus (Estes Energy) Pack Benchmark

Estes Energy Magnus battery pack image

“What are the benefits of a Magnesium battery pack enclosure?” arrived in my inbox with a link to the Estes Energy website. That got me looking at this particular design as a benchmark and also more generally about the use of magnesium as a structural material within the pack design. This post has been built … Read more

Exploring Different Battery Tray Designs

lower battery tray giga casting

Exploring different battery tray designs in the automotive industry and three main design concepts have emerged in the design of metallic battery trays: Building on Posts from Matthias Biegerl [1] and Luca Greco [2]. Deep-Drawn Sheet Metal Pans This process involves forming the housing with deep-drawn sheet metal pans and sealing it with a lid. … Read more

Enhancing Li-Ion Battery Safety

OsecoElfab DualGard breather and vent disc

Integrating Pressure Relief and Breather Devices for Overpressure Mitigation for battery safety. Author: OsecoElfab The rapid growth of Li-Ion batteries in various industries, including electric vehicles, portable electronics, and renewable energy storage has thrown a spotlight onto a critical battery safety concern: thermal runaway and its potential to trigger overpressure explosions. Managing Thermal Runaway To … Read more

IP Ratings

2015 Nissan Leaf Battery

IP Ratings or Ingress Protection ratings are designed to rate and grade the resistance of enclosures of electric and electronic devices against the intrusion of dust and liquids. Plus how easy it is for individuals to access the potentially hazardous parts within the enclosure. The IP rating used for battery packs depends on the specific … Read more

Joining Techniques for Pack Enclosures

lincoln electric welding image

Author: David G. Kilburn & Nigel Taylor As I posted the other day, there are a lot of “boring” battery topics that often get overlooked and producing the battery housing (sometimes referred to as battery tray or box) is no exception! To house a battery you need a high quality, leak proof container that can … Read more