Fraunhofer Institute for Machine Tools and Forming Technology (IWU) and Amsted Automotive have introduced an integrally designed battery housing utilizing aluminum foam sandwich (AAS) structures. The new housing features two solid aluminum sheets enclosing a core of closed-cell aluminum foam, aiming to advance electric vehicle battery pack thermal management and structural integrity.

The AAS housing can be produced in several configurations. Fraunhofer IWU says options include pure AAS, AAS with infiltrated phase change material, AAS with an integrated cooling structure and AAS with both a cooling structure and PCM. The core innovation is the combination of aluminum foam and phase change material, which absorbs or releases heat by transitioning between solid and liquid states without significant temperature change, supporting efficient lithium-ion battery temperature control.

Fraunhofer IWU says integrating PCM within closed-cell aluminum foam enables substantial thermal energy storage or release, which can help manage battery temperatures during operation or charging, a priority for EV manufacturers. Depending on the application, different versions can be tailored to provide structural support, passive thermal management or active cooling.

To facilitate use in high-volume production vehicles, researchers are also emphasizing cost reduction. “We are increasingly using recycled material to produce the aluminum foam,” said Fraunhofer IWU researcher Dr. Thomas Hipke. “Not only is this significantly more cost-effective, but it also greatly reduces the CO₂ footprint,” addressing both price sensitivity and sustainability demands from the automotive sector.

Source: Fraunhofer IWU