Based on previously discussed technology trends, breakthroughs, and new concepts regarding battery enclosures, the core applications of new materials for 2026 are outlined below:
Applications of Lightweight Structural Materials
6-Series Aluminum Alloy: A mainstream lightweight material that is 30% lighter than steel and inherently corrosion-resistant. Widely used in battery enclosures for new energy passenger vehicles, it effectively absorbs impact energy during crash tests while maintaining structural integrity.
High-Strength Steel/Boron Steel Variants: These offer a 20% cost advantage over aluminum alloys and 50% greater puncture resistance; a 1.2mm thickness can withstand 10 tons of pressure. They are frequently used in battery enclosures for commercial vehicles.
Carbon Fiber Reinforced Plastic (CFRP): 40% lighter than aluminum and three times stronger. Its use in high-end models can reduce vehicle weight by 100kg, effectively extending the driving range by 25km; costs are currently decreasing, facilitating wider adoption.
Thermoplastic Composites: With densities only one-quarter that of steel and two-thirds that of aluminum alloy, these materials are recyclable via remelting and are compatible with automated mass-production lines (capable of producing hundreds of thousands of units annually), making them a key focus for industry-wide mass adoption.
Applications of Functional Auxiliary Materials
EVA Foam: Meets UL94 V-0 flame-retardancy standards; used for cell cushioning and enclosure sealing, and widely applied as internal filler for small-to-medium-sized energy storage battery enclosures.
EPP Material: 100% recyclable; used for module spacers within new energy vehicle battery packs and thermal insulation liners for enclosure lids, making it suitable for green, circular packaging applications.
Specialized Epoxy Resin Boards for Battery Enclosures: Secure the battery pack using a sliding locking mechanism, preventing bond interface delamination while facilitating rapid heat dissipation and enhancing structural stability.
Multilayer Composite Heat-Resistant Resin Materials: Composed of an inner thermal insulation layer, a heat-resistant resin layer, and a structural support layer. These materials offer high-temperature resistance and excellent mechanical properties, preventing enclosure collapse or deformation under high heat and containing fires to prevent flame spread.
Modified PVC Materials: Maintain stable insulation at 10kV and have a density only one-fifth that of steel; capable of being molded into complex curved structures in a single step, they are frequently used in lightweight, low-cost battery enclosure designs.