In this paper, a pure electric vehicle is used as the research object. By integrating the characteristics of carbon fiber composite materials, a lightweight power battery box is designed to meet the requirements for reduced weight and improved performance. To enhance sensor signal strength or improve system reliability, a front-end amplifier may be added. Introduction The development of new energy vehicles plays a crucial role in addressing energy and environmental challenges while promoting sustainable growth in the automotive industry. As a core component of the energy supply system, the power battery directly influences the performance of new energy vehicles. The power battery case serves as a protective housing for the battery, playing a vital role in ensuring its safe operation and durability. Traditionally, most electric vehicle battery cases are made from metal materials. However, with advancements in material science, composite materials have increasingly been used in battery case design to enhance economic efficiency and achieve lightweight solutions. In this study, we focus on designing a carbon fiber-based power battery case to meet the growing demand for lighter and more efficient electric vehicles. 1. Design of Carbon Fiber Battery Box 1.1 Functional Requirements of the Battery Case As a protective component for the power battery, the battery case must meet high standards in structural design and weight reduction. Once the size and weight of the battery module are determined, multiple factors must be considered during the design process. First, the case acts as a carrier for the battery module, requiring secure connections. Second, since the power battery is typically installed at the bottom of the vehicle, the case must provide protection against water, dust, corrosion, and vibrations that occur during operation. 1.2 Advantages of Carbon Fiber Materials The ideal material for a power battery case should offer high strength, low weight, and excellent corrosion resistance. Carbon fiber composites excel in all these aspects. They have a high specific strength (tensile strength divided by density) and specific modulus (elastic modulus divided by density), with a specific strength five times that of steel. Additionally, when combined with epoxy resin, carbon fiber has a density of 1.4 kg/m³ and offers superior corrosion resistance and flame retardancy. 1.3 Process Design of Carbon Fiber Battery Box Carbon fiber products can be manufactured using various molding techniques, such as Vacuum Assisted Resin Transfer Molding (VARI) and Resin Transfer Molding (RTM). VARI is cost-effective and suitable for small batch production, while RTM is better for larger parts. Based on production volume and cost considerations, this project selects the VARI process. The VARI process involves placing dry fiber fabrics into a mold, covering them with a vacuum bag, and using vacuum pressure to draw resin into the fibers. After curing, the part is removed and finished accordingly. 1.4 Structural Design of Carbon Fiber Battery Box Figure 1 shows the placement of the power battery within the vehicle body. [Image: http://i.bosscdn.com/blog/pI/YB/AF/q4py2AIQzzAABNGXRb-Cs122.jpg] 1.4.1 Overall Structural Design Based on the shape and layout of the battery modules, the outer envelope of the battery case is designed as a square box to maximize space utilization. The main structure is made of carbon fiber cloth reinforced with resin, and metal joints are used to connect different sections. Structural adhesives and fasteners are employed to ensure strong and durable connections between the battery modules and the case. To increase strength and stiffness, ribs and hat-shaped structures are incorporated into the design. These features enhance structural stability without adding excessive weight. The carbon fiber reinforcement is specially designed to provide sufficient thickness at critical areas. 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 [0°/45°/0°/45°/0°/0°/45°/0°/45°/0°], ensuring balance, symmetry, and optimal load distribution. 1.4.3 Connection Design The battery modules are connected to the vehicle body through the battery case. Metal fasteners are embedded in the case and bonded using structural adhesives to ensure strong mechanical connections. 2. Simulation Analysis of Carbon Fiber Power Battery Box This study simulates and analyzes the structural performance of the carbon fiber power battery box under four conditions: G-load, modal analysis, vibration, and shock. These analyses help evaluate the durability and optimize the design of the battery system. 2.1 G-Load Analysis Table 1 presents the G-load conditions applied to the battery system, simulating real-world driving scenarios such as braking, turning, and acceleration. The results show that the maximum stress under severe conditions is well below the material's allowable stress. [Image: http://i.bosscdn.com/blog/pI/YB/AF/q4py6AUCy8AAAO8pZvjAg822.png] 2.2 Modal Analysis Modal analysis determines the natural frequencies and mode shapes of the structure. For the battery case, the first six natural frequencies were analyzed. The first mode was found to be 61 Hz, which meets the requirement of avoiding high-vibration zones (35–40 Hz). [Image: http://i.bosscdn.com/blog/pI/YB/AF/q4py6AdrRUAAA353anW84156.jpg] 2.3 Mechanical Shock Analysis According to ISO 16750 standards, the battery case was tested for mechanical shock resistance. The peak acceleration was set to 500 m/s² for 6 ms in six directions. The results showed that the maximum stress was 76.5 MPa, significantly lower than the material’s allowable stress. 2.4 Vibration Analysis Based on SAE J2380 standards, the vibration resistance of the battery case was evaluated. The simulation results confirmed that the maximum stress remained well within the acceptable range, validating the structural integrity of the carbon fiber case. 3. Conclusion This study explores the use of carbon fiber composites for lightweight power battery box design and verifies the design through finite element analysis. The results demonstrate that the carbon fiber composite battery case fully meets structural, mechanical, and fatigue requirements. The carbon fiber case weighs 12 kg, compared to 15.5 kg for an SMC composite case, achieving a 3.5 kg weight reduction, or a 22% improvement in weight efficiency.

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