Impact Response of a Thermoplastic Battery Housing for Transport Applications

The transition to electric mobility has intensified efforts to develop battery technologies that are not only high-performing but also environmentally sustainable. A critical element in battery system design is the structural housing, which must provide effective impact protection to ensure passenger safety and prevent catastrophic failures. This study examines the impact response of an innovative sheet molding compound (SMC) composite battery housing, manufactured from an Elium resin modified with Martinal ATH matrix, reinforced with glass fibers, that combines fire resistance and recyclability, unlike conventional thermoset and metallic housings. The material was characterized through standardized mechanical tests, and its impact performance was evaluated via drop-weight experiments on plates and a full-scale housing. The impact tests were conducted at varying energy levels to induce barely visible impact damage (BVID) and visible impact damage (VID). A finite element model was developed in LS-DYNA using the experimentally derived material properties and was validated against the impact tests. Parametric simulations of ground and pole collisions revealed the critical velocity thresholds at which housing deformation begins to affect the first battery cells, while lower-energy impacts were absorbed without compromising the pack. The study provides one of the first combined experimental and numerical assessments of Elium SMC in battery enclosures, emphasizing its potential as a sustainable alternative for next-generation battery systems for transport applications.