Lightweight Design of EV Lower Battery Boxes Using

Aojie Liang

doi:10.54254/2755-2721/2026.KA28778

Applied and Computational EngineeringOpen access

Lightweight Design of EV Lower Battery Boxes Using

Research Article

Open Access

Lightweight Design of EV Lower Battery Boxes Using

Aojie Liang ^1*

¹ Huijia Private School

^*Corresponding author: harryliang0730@gmail.com

Published on 28 October 2025

ACE Vol.200

ISSN (Print): 2755-273X

ISSN (Online): 2755-2721

ISBN (Print): 978-1-80590-491-5

ISBN (Online): 978-1-80590-492-2

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Abstract

With the rapid rise of electric vehicles, lightweight design of battery boxes has become a critical focus to enhance driving range and reduce carbon emissions. The lower battery box offers greater flexibility for structural and material innovation due to fewer functional constraints. This paper focused on the application of vinyl ester prepreg composites as a substitute for traditional metal structures to achieve weight reduction while maintaining safety. Previous research shows that most studies concentrate on simulation and topology optimization, while few directly analyze material performance. This study compared epoxy, phenolic, and vinyl ester prepregs, demonstrating that vinyl ester prepreg exhibits superior mechanical properties, hygrothermal aging resistance, and impact toughness. Furthermore, assembly using polyurethane adhesives ensures both bonding strength and airtightness. The study concluded that a hybrid structure combining prepreg composites and metal alloys can achieve a weight reduction target of 22.6% while meeting the performance requirements of electric vehicle lower battery boxes.

Keywords:

Electric vehicles (EVs), Lower Battery Box, Vinyl-ester Prepreg, Lightweighting.

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References

[2]. Liu, Y., Liu, C., Tan, J., He, Y., Li, F. and Zhang, T. (2024) Optimization and structural analysis of automotive battery packs using ANSYS. Symmetry, 16(11), 1464.

[4]. Shao, J., Lin, C., Yan, T., Qi, C. and Hu, Y. (2022) Safety characteristics of lithium-ion batteries under dynamic impact conditions. Energies, 15(23), 9148.

[5]. Xia, Y., Wierzbicki, T., Sahraei, E. and Zhang, X. (2014) Damage of cells and battery packs due to ground impact. Journal of Power Sources, 267, 78-97.

[10]. Zhang, J., Zhang, Z., Huang, R. and Tan, L. (2025) Advances in toughening modification methods for epoxy resins: A comprehensive review. Polymers, 17(9), 1288.

[16]. Qiu, M., Chen, L. and Li, X. (2025) Random vibration isolation of a semi-submersible marine platform using a quasi-zero stiffness system. Ocean Engineering, 320, 120334.

Cite this article

Liang,A. (2025). Lightweight Design of EV Lower Battery Boxes Using. Applied and Computational Engineering,200,50-56.

Data availability

The datasets used and/or analyzed during the current study will be available from the authors upon reasonable request.

About volume

Volume title: Proceedings of CONF-MCEE 2026 Symposium: Advances in Sustainable Aviation and Aerospace Vehicle Automation

ISBN: 978-1-80590-491-5(Print) / 978-1-80590-492-2(Online)

Editor: Ömer Burak İSTANBULLU

Conference website: https://2025.confmcee.org/kayseri.html

Conference date: 14 November 2025

Series: Applied and Computational Engineering

Volume number: Vol.200

ISSN: 2755-2721(Print) / 2755-273X(Online)

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