In this paper, a pure electric vehicle is selected as the research subject. By integrating the unique properties of carbon fiber composite materials, a lightweight power battery box is designed to meet the requirements of reduced weight and improved performance. The system also includes sensor enhancements or the addition of a front-end amplifier to ensure reliable data transmission and monitoring. **Introduction** The development of new energy vehicles plays a crucial role in addressing global energy and environmental challenges while promoting sustainable growth in the automotive industry. As a core component of new energy vehicles, the power battery significantly influences the overall performance of the vehicle. The power battery box serves as the housing for the battery and is essential for ensuring its safe operation and protection. Traditionally, power battery cases have been made from metal materials. However, with advancements in material science, composite materials are increasingly being used to enhance the economic efficiency and reduce the weight of power batteries. This shift has led to the adoption of carbon fiber composites in battery box design, offering both structural integrity and weight reduction benefits. In this study, a carbon fiber-based power battery box is designed for a pure electric vehicle, leveraging the advantages of carbon fiber composites to meet the demands of lightweight and high-performance battery systems. Sensor upgrades or the integration of a front-end amplifier are implemented to improve the system’s reliability and functionality. **1. Design of Carbon Fiber Battery Box** **1.1 Functional Requirements of the Battery Box** As a protective component for the power battery, the battery case must meet strict structural and weight requirements. Once the size and weight of the battery module are determined, several factors come into play during the design process. First, the battery case acts as a carrier, connecting the battery module securely. Second, since the power battery is typically located at the bottom of the vehicle, the case must provide protection against water, dust, corrosion, and mechanical vibrations during operation. **1.2 Advantages of Carbon Fiber Materials** Carbon fiber composites offer significant advantages in terms of strength, weight, and corrosion resistance. Their high specific strength—five times that of steel—and low density (around 1.4 kg/m³ when combined with epoxy resin) make them ideal for lightweight applications. Additionally, they exhibit excellent resistance to corrosion and flame, making them suitable for use in harsh environments. **1.3 Process Design for Carbon Fiber Battery Boxes** Carbon fiber products can be manufactured using various molding techniques, such as Vacuum Assisted Resin Transfer Molding (VARTM) and Resin Transfer Molding (RTM). VARTM is cost-effective for small-batch production and allows for high fiber content, while RTM is more suitable for large parts. Based on production requirements and cost considerations, the VARTM process was selected for this project due to its efficiency and compatibility with current domestic manufacturing capabilities. The VARTM process involves placing dry carbon fiber fabrics in a mold, sealing it with a vacuum bag, and using vacuum pressure to draw resin into the fibers. After curing, the part is removed, trimmed, and finished to meet design specifications. **1.4 Structural Design of the Carbon Fiber Battery Box** The position of the power battery on the vehicle body is illustrated in Figure 1.  **1.4.1 Overall Structural Design** Based on the shape and arrangement of the battery modules, the outer envelope of the battery box is designed as a square-like structure to maximize space utilization. The main structural layer consists of carbon fiber cloth reinforced with resin. Metal joints are used at the connections, bonded with structural adhesives. Fasteners are employed to secure the battery module group to the box. To enhance structural stability, ribs and hat-shaped structures are incorporated. These features improve load distribution and reduce weight while maintaining strength. The design ensures that the carbon fiber structure is optimized for performance and durability. **1.4.2 Ply Design** The battery case uses T300-3K and T300-12K carbon fiber woven fabrics, combined in a total of 10 layers. The lamination sequence follows a balanced pattern: [0°/45°/0°/45°/0°/0°/45°/0°/45°/0°], ensuring uniform stress distribution and structural integrity. **1.4.3 Connection Design** The battery module is connected to the vehicle body through the battery box. Metal fasteners are embedded in the box to provide strong mechanical connections. Some fasteners are bonded to the carbon fiber structure using structural adhesives, enhancing the overall strength and durability of the system. **2. Simulation Analysis of the Carbon Fiber Power Battery Box** This section presents a comprehensive simulation analysis of the carbon fiber power battery box, covering G-load, modal, vibration, and shock resistance. These analyses provide valuable insights for improving the durability and optimizing the structure of the power battery system. **2.1 G-Load Analysis** Four different loading conditions were simulated to evaluate the structural strength of the battery under various driving scenarios, including braking, turning, and jumping. The results show that the maximum stress under severe conditions is well below the allowable stress of the material, confirming the safety and reliability of the design. **2.2 Modal Analysis** Modal analysis was conducted to determine the natural frequencies and vibration modes of the battery box. The first-order mode frequency was found to be 61 Hz, which meets the requirement of avoiding resonance in the 35–40 Hz range, as specified by the J2380 standard. **2.3 Mechanical Shock Analysis** Using the ISO 16750 standard, the mechanical shock resistance of the battery box was analyzed. A half-sinusoidal pulse with a peak acceleration of 500 m/s² and a duration of 6 ms was applied. The results showed that the maximum stress was only 76.5 MPa, far below the material's allowable limit. **2.4 Vibration Analysis** Based on the SAE J2380 standard, the vibration resistance of the battery box was evaluated. The results confirmed that the maximum stress was significantly lower than the material's allowable stress, demonstrating the effectiveness of the design. **3. Conclusion** This paper explores the use of carbon fiber composites in the lightweight design of power battery boxes. The design was validated through finite element simulations, confirming that the carbon fiber battery case meets all structural and mechanical requirements. Compared to an SMC composite battery case, the carbon fiber version weighs 12 kg, resulting in a 3.5 kg weight reduction—equivalent to a 22% improvement. This demonstrates the potential of carbon fiber composites in advancing the performance and efficiency of electric vehicles.

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