Autoneum BEV battery lid prototype unites multifunctionality and composites

Source | Autoneum

Autoneum (Winterthur, Switzerland) is publicly debuting its novel composite battery lid prototype, a multifunctional component that simplifies battery pack design while meeting the key safety and performance requirements of modern battery-electric vehicles (BEV).

Functionally, the battery lid is conceived as a highly adaptable top cover for the battery pack. Its composite structure allows the integration of additional functional layers, such as flame-retardant (FR) layers or electromagnetic shielding, depending on vehicle and platform requirements. 

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“By consolidating functions that previously required multiple individual components — such as a separate battery lid and a flame shield — our solution reduces assembly complexity and effort,” says Luca Mazzarella, head new mobility at Autoneum. “We can replace two or more parts with a single one.”

Manufactured using spray transfer molding (STM), the battery lid is glass fiber-reinforced polyurethane, offering high mechanical strength, formability for complex 3D shapes and tight radii, and thin part thickness for lightweight potential. The STM process achieves fast production cycles, design flexibility and 30% weight saving compared to traditional manufacturing methods.

From a safety perspective, the battery lid is a further development of Autoneum’s flame shield technology, achieving enhanced thermal and electrical insulation properties and improved thermal runaway confinement. Both the battery lid and flame shield are produced without mica, addressing sustainability and supply chain concerns associated with conventional flame protection materials.