Battery System

Plastics are essential as electrical insulators, making them ideal for high-voltage battery applications where resistance to short-term high temperatures from arc events is crucial. Envalior provides a diverse range of customized plastics engineered to meet these rigorous demands.

Flame-retardant PBTs and PBT blends are preferred for dimensionally critical components like pouch cell frames and round cell carriers. For overmolded busbars, PA6 or PA66 with varied glass fiber content and FR additives are employed to withstand thermal shock. Thermally conductive grades further enhance performance by promoting even temperature distribution and reducing peak temperatures in sensitive components.

Every battery system requires reliable thermal management to maximize efficiency and longevity. Dielectric fluids offer the most effective temperature control by fully immersing the cells in electrically non-conductive liquid, making them especially ideal for round cells. At Envalior, we’ve rigorously tested various grades with different dielectric fluids to ensure optimal compatibility, preserving plastic integrity and preventing fluid contamination from leaching. Typical applications include round cell holders, bus bars, and structural elements designed to protect cells in case of impact.

Thermoplastic battery enclosures offer a practical and efficient alternative to traditional metal designs. By using a one-piece tray, they help reduce weight by more than 15%, simplify the assembly process, and allow for smart integration of features like thermal management and direct mounting points. With up to 45% lower CO₂ emissions compared to aluminum enclosures, they support efforts to make vehicles more environmentally friendly and sustainable. Thanks to their natural electrical insulation and straightforward recyclability, thermoplastic enclosures make it easier to meet performance, safety, and sustainability requirements in modern battery system design.