Battery boxes are essential in ensuring the safety, performance, and longevity of energy storage units and battery systems. These protective enclosures are designed to securely house one or more batteries in a purpose-built container. They have various applications, including backup battery storage units, exchangeable packs for electric vehicles, battery-powered industrial equipment like electric forklifts, and solar power storage systems.

Due to their critical role, battery boxes must be designed with meticulous attention to various factors. Here are things to consider:

1. Material

Choosing the right materials is paramount in designing a battery box that can withstand the challenges of its environment. The materials should be corrosion-resistant, durable, and able to provide thermal insulation. Weight is also a factor in material selection to ensure the overall assembly meets the design requirements.

Common materials include stainless steel, steel, or aluminum, each with pros and cons. The choice depends on factors such as battery weight, cost, grounding requirements, finishing specifications and compatibility with dissimilar metals.

2. Configuration and Connections

In multi-cell battery boxes, meticulous attention to battery and wiring configuration is crucial. The arrangement of positive and negative connections and the overall system configuration impacts performance, safety, and efficiency.

Designers must account for serial or parallel configurations, depending on the application’s specific requirements. Additionally, it is imperative to implement shielding for bus-bar connections or wires and proper arrangement of positive and negative battery connections. These ensure the safety and efficiency of the overall system.

3. Safety Standards

Safety is non-negotiable when it comes to battery box fabrication. Depending on the application, different safety standards and considerations may apply. Key considerations include implementing measures for leak containment, battery cooling, and securely placing battery cells to prevent damage.

Lifting points must be meticulously designed to handle the intended load. Additionally, the overall engineering of the box should consider the ability to withstand potential battery fires or explosions. Adequate guarding should also be taken into account to prevent shocks and short circuits and ensure a safer operational environment.

4. Special Provisions

Battery boxes often require additional features for enhanced functionality and adaptability. For instance, integrating human-machine interfaces (HMIs), such as touchscreens or control panels, enhances user interaction and provides convenient monitoring and control of the battery system.

Other convenient features include shut-off or disconnect switches, display screens, grounding studs, and unmasked areas for conductive or grounding connections. These provisions are tailored to specific application needs, ensuring the battery box meets unique requirements for improved efficiency and user convenience.

5. Protective Coatings

Proper coating specifications contribute to the overall longevity and durability of the battery box.

Key factors include ensuring the appropriateness of dielectric paints for electrical insulation and assessing the coating’s durability against normal handling over the system’s lifetime. Moreover, the coating must protect against corrosion if the material is exposed to oxidizing agents.

Choose JVC Precision for Custom Battery Box Fabrication

JVC Precision is a trusted partner in designing and building custom battery boxes for battery electric vehicles (BEVs), industrial equipment, and off-grid storage scenarios! Our boxes are optimized with grounding studs and precise paint masking, guaranteeing enhanced functionality and sustained performance. Moreover, all our products are crafted with precision forming and assembly techniques, including specialty coatings for improved durability.

Contact us now to discuss your project or request a quote to get started!