September 25, 2023

Reusable packaging for lithium-ion EV batteries

Reusable packaging for lithium-ion EV batteries

Reusable packaging solutions for lithium-ion EV batteries

As the demand for electric vehicles powered by lithium-ion batteries continues to grow, it is becoming increasingly important that packaging engineers select specialized packaging solutions for transporting and storing Li-ion batteries.  As businesses worldwide respond to EV demand, it raises the need for safe and reliable battery packaging adhering to national and international regulations.

What is the current landscape of Li-ion battery packaging solutions

About 20% of the world's energy consumption is attributed to transportation, with passenger vehicles contributing nearly 10% of total energy-related carbon dioxide emissions. As personal vehicle ownership continues to surge, so does the demand for fuel. However, the continuous evolution of technology is revolutionizing the electric vehicle (EV) industry, poised to be one of the most effective ways to reduce emissions and global oil consumption.

Hybrid electric and plug-in vehicles can help decrease government reliance on oil imports, thus increasing energy security. EVs can draw power from off-board electric sources, eliminating the need to import fuel from politically unstable regions.

As EVs continue to become more prevalent on our roads, the manufacturing industry is acutely aware of the importance of creating reliable and safe Li-ion battery packaging solutions. Not only must these solutions be durable, but they also must safely transport and store EV batteries while mitigating battery hazards.  The current landscape of Li-ion battery packaging solutions is rapidly evolving, with various new materials such as elastomer coatings and EBE self-extinguishing foams.

Benefits of using reusable packaging solutions

In a world that is becoming increasingly environmentally conscious, reusable packaging for Li-ion batteries goes beyond just environmental benefits. For instance, it can be designed to meet or exceed regulatory standards for safely transporting hazardous Li-ion batteries. This ensures that safety protocols are consistently followed.  Additionally, it can help mitigate the hazards of thermal runaway, a dangerous heat buildup and fire that can occur to damaged batteries. Not only that, but companies that use reusable packaging solutions often see a reduction in their overall packaging expenses.

Challenges of storing and shipping Li-ion battery cells, modules, and packs

As the popularity of electric vehicles continues to rise, so do the challenges of handling, storing, and shipping Li-ion batteries. Increased regulations from organizations like the Department of Transportation (DOT) and the International Air Transport Association (IATA) pose significant hurdles.  Shipping lithium batteries requires adherence to strict packaging guidelines to prevent the risk of fire or explosion.

The rules governing packaging differ based on the transportation method and the dimensions and volume of the batteries involved. Nonetheless, the overarching objective is consistent: to create packaging that averts hazardous conditions by preventing damage. Ensuring that batteries are safeguarded from short circuits and shifting during transit is a crucial aspect of the packaging blueprint. Despite these challenges, many companies continue developing innovative packaging solutions to ensure the safe and efficient transportation of Li-ion batteries for EVs.

How to choose the best reusable packaging solution for your needs

When choosing the best packaging solutions for your Li-ion needs, navigating the sea of options can be overwhelming. That's why turning to an expert in the field can make all the difference. Look for a company that can provide compliant packaging solutions and design and manufacture custom packaging to meet your specific needs. Additionally, if you require certified EV battery packaging, ensure the company has the necessary certifications to provide peace of mind, knowing your products comply with the latest rules and regulations.

With a wealth of experience and expertise, PackIQ offers an array of UN-certified packaging solutions crafted from diverse materials to meet the unique needs of each application. Our specialized packaging for Li-ion batteries undergoes rigorous testing and certification, adhering to UN Recommendations and other regulatory guidelines. For example, our Clip-Lok crates use specialized materials, elastomer coatings, and EBE self-extinguishing foam to meet the requirements of 49 CFR 173.185 and/or UL 94. Our design approach guarantees that your batteries are shielded from the unpredictable elements of transit, ensuring a secure and successful journey to their final destination.

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