The use of a polymer composite material in electric vehicles (EVs) has been extensively investigated, especially as a substitute for steel. The key objective of this manuscript is to provide an overview of the existing and emerging technologies related to the application of such a composite, especially for battery pack applications, in which its high strength-to-weight ratio, corrosion resistance, design flexibility, and durability are advantageous compared to any metal in general. This study explores the key considerations in the design and fabrication of composites, including base material selection, structural design optimization, reinforcement material, manufacturing processes, and integration with battery systems. The paper also discusses the performance characteristics of composite battery pack structures, such as mechanical properties, thermal management, safety aspects, and environmental sustainability. This study aims to contribute to sharpening the direction of future research and innovations in the area of composite battery pack technology.

A composite container for an electric vehicle (EV) battery module filled with a phase-change material (PCM) was experimentally tested at various discharge rates. The average cell temperatures at 1 C, 2 C, and 4 C discharge rates, respectively, might reach 38 °C, 50 °C, and 70 °C in the absence of any heat-absorbing material. The temperature was noticeably lower with PCM present than with a conventional battery module. For instance, at 4 C discharge rates, none of the battery cells inside the PCM-filled module were able to reach 70 °C. Unfortunately, the PCM addition also degraded the composite’s tensile qualities. Further investigations used Paraffin-20 and Caprylone since PCMs provide a notably different thermal performance due to their distinctive latent heat profiles. It was observed that a high melting temperature of the paraffin mixture, despite its slightly lower latent heat capacity compared to Caprylone, could lead to a more uniform temperature. Overall, both PCMs can be used as passive protection against any potential thermal abuses in EV battery modules, while in terms of mechanical strength, the use of a composite reinforcement material is strongly encouraged.

Steer-by-wire (SbW) is the latest steering evolution, providing many benefits, such as reduced vehicle weight and enhanced steering capability. While reliability is one of the main concerns hindering its widespread application, the potential of this technology to revolutionize the automotive industry is huge. Control techniques play an important part in achieving the full potential of SbW by focusing on the development of its performance and safety aspects. This paper provides a review of the control techniques that are being used in SbW technology to achieve better performance and enhance safety. Various control techniques for SbW exist to serve different purposes when dealing with the non-linear nature of the SbW dynamics. Although there is no one-size-fits-all control technique for all the requirements of the SbW, this study highlights that the non-linear controllers based on the sliding mode control (SMC) are a popular option for enhancing the accuracy of SbW systems. However, these controllers often suffer from a downside known as chattering. In contrast, robust controllers like Model Predictive Controllers (MPCs) can effectively manage uncertain dynamics and eliminate chattering, although they pose challenges due to their high computational costs.

Electrical energy consumption of a converted electric vehicle in the real-world environment has been examined. The objective of such test is to compare the overall energy consumption of a vehicle with and without regenerative braking features. For each test, sets of data such as the total testing time, the batteries charge and/or discharge power, and the vehicle mileage were collected and analyzed to determine the energy consumption. The reliability of the data was tested using confidence intervals, which could be used as an indication of the level of confidence that the average value taken could represent the average population. The average value of energy consumption in the vehicles with and without regenerative braking is 145.26 Wh/km and 154.79 Wh/km, respectively. The difference between the average energy consumption from those two conditions, which is 9.53 Wh/km, has 95% probability to be accurate, as indicated by the confidence intervals test. This shows a decrease in electrical energy consumption by about 6.16%, which indicates an enhancement in mileage or vehicles efficiency.

One of the safety requirements for the vehicle components is in terms of the flammability factor. Generally, the polymer material used for vehicle components is Unsaturated Polyester (UP). Unfortunately, this material is highly flammable. The addition of Aluminum Tri-Hydroxide (ATH) to UP is known to improve its flame retardancy, but its material strength is compromised. Moreover, the use of pristine Montmorillonite (MMT) rather than the commonly used organomodified MMT as a mixture to the ATH results in different material characteristics that could potentially minimise such a reduction of material strength. This manuscript discusses the combination of ATH and MMT in Glass Fiber Reinforced Polymer (GFRP) composites, specifically in terms of mechanical properties and flame retardancy. The increase of ATH content to UP decreases the flexural strength of GFRP, ranging from 34.3% to 63.4% lower than the neat GFRP. A slight increase of flexural strength is found in samples with ATH and MMT combinations (CA45M15), indicating that the addition of MMT does not dramatically change the flexural strength of GFRP. However, the addition of filler ATH, MMT, or a combination of both could increase the flame retardancy of GFRP. The addition of ATH leads to a slight increase of the UP initial temperature of decomposition, while the addition of MMT shows almost no notable differences. The flammability test shows that the additions of ATH, MMT or their combinations tend to decrease the rate of linear burning. Therefore, it can be concluded that the ATH and MMT could effectively improve the flame retardancy of GFRP.

Lithium-ion batteries are fundamental to modern electric vehicles, offering high energy density, long cycle life, and low self-discharge rates. However, thermal runaway—a critical safety issue involving uncontrolled temperature increases—can lead to fire or explosion. Ensuring flame retardancy is crucial in accidents where battery packs are exposed to external fires. Additionally, battery packs are susceptible to mechanical stresses and potential damage from ground impacts like debris or uneven road surfaces. Effective thermal management significantly impacts capacity and longevity. This review emphasizes the importance of researching flame retardancy, ground impact resistance, and thermal management, especially in composite battery enclosures. Composites serve as a lightweight alternative to metals and help overcome one of the main constraints of EVs, which is weight. Ground impact refers to the physical force battery packs endure during collisions, hitting potholes, debris, or accidents. Therefore, understanding the effects of ground impact on battery enclosures is crucial for design considerations. Effective thermal management is also essential, as it directly affects the performance and safety of Lithium-ion battery packs in EVs.