Electromagnetic Interference (EMI) Shielding and Thermal Management of Sandwich-Structured Carbon Fiber-Reinforced Composite (CFRC) for Electric Vehicle Battery Casings.

In response to the growing demand for lightweight yet robust materials in electric vehicle (EV) battery casings, this study introduces an advanced carbon fiber-reinforced composite (CFRC). This novel material is engineered to address critical aspects of EV battery casing requirements, including mechanical strength, electromagnetic interference (EMI) shielding, and thermal management. The research strategically combines carbon composite components with copper-plated polyester non-woven fabric (CFRC/Cu) and melamine foam board (CFRC/Me) into a sandwich-structure composite plus a series of composites with graphite particle-integrated matrix resin (CFRC+Gr). Dynamic mechanical analysis (DMA) revealed that the inclusion of copper-plated fabric significantly enhanced the stiffness, and the specific tensile strength of the new composites reached 346.8 MPa/(g/cm), which was higher than that of other metal materials used for EV battery casings. The new developed composites had excellent EMI shielding properties, with the highest shielding effectives of 88.27 dB from 30 MHz to 3 GHz. Furthermore, after integrating the graphite particles, the peak temperature of all composites via Joule heating was increased. The CFRC+Gr/Me reached 68.3 °C under a 5 V DC power supply after 180 s. This research presents a comprehensive and innovative approach that adeptly balances mechanical, electromagnetic, and thermal requirements for EV battery casings.