Product Specifications
|
Specification |
Available Range / Standard |
|
Applications and Cells |
E-bike, electric scooter, electric motorcycle, light EV, robot, or auxiliary module; 18650, 21700, 26650, 32700, prismatic, or pouch cells |
|
Housing Materials |
FR-ABS, PC/ABS, PP, flame-retardant PP, and reinforced PA grades |
|
Wall Thickness / Size |
2.0-4.0 mm wall thickness; 100-600 mm housing size |
|
Flammability |
UL 94 HB / UL 94 V-0 |
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Assembled Enclosure Ingress / Impact |
IP54 / IP65 / IP67; IK07-IK08 |
|
Operating Temperature |
ABS / PP systems: -20°C to +60°C; PC/ABS systems: -40°C to +110°C |
|
Gasket And Closure |
Silicone, EPDM, or TPE gasket with screws, snap fits, ultrasonic welding, or bonded lid |
|
Vent And Cable Interface |
M12 / M16 pressure-equalization vent, cable gland, connector seat, or sealed port |
|
Functional Test Capability |
1.0 m drop test, IEC 60068-2-6 vibration, -20°C to +60°C thermal cycling, and leak test |
|
Supply Scope |
Base and lid, cell holders, rails, locks, handles, brackets, or defined mechanical assembly |
Key Features
● Flame-Retardant Insulating Structure
FR-ABS, PC/ABS, PP, and other specified insulating grades can be molded with ribs, bosses, cell supports, and reinforced mounting points. Around the cells, busbars, fuses, and BMS, the resin and wall structure separate conductive parts and resist deformation from handling, vibration, and normal charging heat.
● Sealing And Pressure-Management Interfaces
The enclosure can include gasket grooves, lid flanges, cable glands, connector seats, drain paths, ultrasonic-weld ribs, screws, and pressure-equalization vent seats. For outdoor packs exposed to rain and temperature cycling, these interfaces support the target ingress rating and reduce seal stress caused by internal pressure changes.
● Internal Layout And Vehicle Mounting Integration
Cell trays, BMS brackets, fuse pockets, cable channels, lock interfaces, handles, rails, and frame mounting points are arranged around the approved pack architecture. This structure helps control cell movement, cable abrasion, loose electronics, and misalignment with the vehicle mount during road shock and repeated battery removal.
Customization Options
● Internal Pack Layout
Customize the cell format and module dimensions, plus the positions of the BMS and connectors.
● Housing And Sealing
Specify the resin, lid-closure method, and gasket or vent structure for the target enclosure.
● Vehicle Interface
Define the mounting format, rail or lock system, and external port or indicator locations.
Customization Process
Requirement Confirmation
Confirm the battery-module layout, vehicle mounting interface, and sealing or flame-retardant requirement.
Engineering Review
Validate internal clearances, insulation spacing, and gasket or lock engagement.
Mold Design And Manufacturing
Develop the mold around the large housing geometry and the controlled sealing surfaces.
Trial Molding And Sample Approval
Assemble the trial housing with the defined pack components and approve closure, leakage, and mount operation.
Production And Inspection
Control material specification, sealing dimensions, inserts, and vehicle-mounting points in each lot.
Packing And Delivery
Protect sealing flanges, rails, locks, and corners, then label the model and orientation.
Quality Control
● Material And Flame-Retardant Documentation
Before molding, the approved resin grade, lot, color, reinforcement, and flame-retardant requirement are verified. Supplier declarations or test reports are collected when the project requires them.
● Sealing-Surface And Assembly Inspection
Inspection covers the lid and base dimensions, gasket grooves, connector seats, vent locations, mounting rails, locks, bosses, and flat sealing faces. Measurements are made with tools, fixtures, and the approved assembly.
● Functional Validation
The agreed pack requirement may call for leak, drop, vibration, thermal cycling, lock cycling, or load tests. Before packing, finished housings are checked for cracks, short shots, warpage, damaged inserts, and sealing defects.
FAQ
Q1: What are the payment terms for a custom battery-box project?
A1: The mold-development fee is paid in advance, followed by a goods deposit. For EXW or FOB, the balance is paid after container loading and sealing. For CIF, it is paid before release of the bill of lading.
Q2: How are battery boxes packaged for export?
A2: Lids and bases are protected at the sealing faces, rails, locks, corners, and visible surfaces. Formed supports, separators, bags, and export cartons are selected for the size and stacking load, and each package carries model and orientation labels.
Q3: Are battery cells, the BMS, and electrical components included?
A3: The standard scope covers the molded plastic housing and the defined mechanical parts. Cells, BMS boards, busbars, fuses, connectors, locks, rails, and wiring are included only after the bill of materials, suppliers, assembly method, and electrical tests are approved.
Q4: Can this plastic box be used as a passenger-car traction-battery enclosure?
A4: This use requires project-specific validation for structure, crash, thermal behavior, fire, sealing, venting, electrical performance, and regulations. The standard molded housing is more commonly used for e-bikes, scooters, light EVs, robots, and auxiliary battery modules than for a full passenger-car traction pack.
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