Thermal Performance Optimization of EV Battery Module Electric Boxes: A Comparative Study of Alternative Housing Materials

Thermal management plays a vital role in the performance, safety, and reliability of electric vehicle (EV) battery systems. This study focuses on the thermal performance optimization of EV battery module electric boxes, with particular attention to the influence of housing materials on heat dissipation. As high-voltage battery systems are critical components in EVs, their thermal behavior directly impacts efficiency, safety, and overall performance. The study addresses the transition from conventional aluminum housings to thermoplastic alternatives, which offer advantages in weight reduction, cost, and corrosion resistance but exhibit lower thermal conductivity.

Through a combination of computational modeling, steady-state and transient simulations, and comparative analysis of different housing configurations, the thesis investigates heat generation and dissipation within the electric boxes, evaluates alternative thermal management strategies, and proposes optimized solutions. The work aims to provide a systematic methodology for enhancing the thermal performance of EV battery modules while balancing material, design, and operational constraints.