As Automotive OEMs Target Increasing Electrified Vehicle Range (=300 miles) And Decreasing Charge Time (=15min), What Are The Trade-Offs In System Design, Opportunities And Challenges? The battery is a key feature for both cost and performance, and its chemistry and cell levels are extensively discussed. At pack and module level (beyond the cell) there are huge material opportunities; a key part of this is how the cells are protected, connected and allowed to dissipate heat.

The most prevalent challenges continue to be based around thermal management, maintaining the temperature essential for performance; a challenge set to greaten with the rise of up to 350 kW fast charging on the horizon. With aggressive battery charging for vehicles come concerns of reduced life and temperature stability. This series takes a deep dive look at enabling materials and technologies, such as advanced thermal management and high voltage architectures, that are set to aid the charging gap and customer range anxiety.
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BEV THERMAL MANAGEMENT INNOVATION

In Europe bringing forward the ban on the sale of new petrol and diesel cars to 2030 means that advancing efficiency benefits to existing battery technologies has never been more crucial.

Every manufacturer has their own methodology to thermally manage their batteries with no clear consensus on the most effective design. Companies like Tesla are set on their patented water-glycol coolant lines which “snake” their way between the cylindrical cells in the pack, whereas OEMs like Nissan and Toyota are committed to air cooling. Active cooling of batteries with fluids are effective, but these significant advantages come at the expense of weight, complexity and cost.

In addition to the more widely adopted technologies, there are other emerging alternatives such as immersion cooling and phase change materials, and these technologies are gaining traction. Practically no EV battery pack has the same design from the cell form (cylindrical, pouch, prismatic) to thermal management employed; typically air, liquid, or refrigerant in either an active or passive capacity. Immersion cooling is an emerging opportunity that we will look at over the webinar series, that is beginning to find market traction. The location of the TIM can also vary widely, and this is also something that we will explore in detail.

There are also numerous material considerations: through-plane conductivity, viscosity, adhesiveness, compressive strength, lifetime, and more. Then there are the factors of cost, application method, and the wider manufacturing impact.

Faced with the on-going restrictions that prevent us from meeting in person, once again WeAutomotive Group will deliver high-quality solution orientated content that addresses the key and current Battery Thermal Management innovation challenges – keeping the industry connected in an easily accessible, direct format.

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MON-10-MAY 11.00am (CET)

Thermal Management And Packing Solutions For Battery Modules

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  • Design and materials to achieve more efficient packaging
  • Thermal material solutions, from steel and aluminum liquid plates, to heat pipes, vapour chambers and encapsulated APG

MON-10-MAY 13.00pm (CET)

Exploring Different Cooling Strategies For Fast Charging And High Performance Electric Vehicles

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  • Identifying challenges and reviewing opportunities of liquid cooling solutions for battery thermal management
  • Thermal management of battery packs using novel submerged-cell cooling technology

MON-10-MAY 15.00pm (CET)

Next Generation Silicone Solutions for xEV Battery Challenges

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Michael Kalchauer, Technical Manager, WACKER Chemie AG

Dr. Sebastian Rommel, Global Segment Manager Automotive, WACKER Chemie AG

 Speaker Biographies | Company Profile

Wacker
  • How Wacker supports automotive OEMs and TIER-Xs by providing silicone light-weight technologies, battery safety solutions and customer dedicated process and product development
  • How innovative silicone solutions contribute to reliable thermal management and protect against thermal propagation in multiple battery applications
  • Next GEN gap-filler solutions for e-Mobility target applications

MON-10-MAY 12.00pm (EST)

Innovative Thermal Interface Materials: How Adhesives And Sealants Are Accelerating xEV’s

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Nick Cupelli, Senior Application Engineer, Parker LORD Corporation

Speaker Biography | Company Profile

Parker Lord
  • Identifying Trends in Thermal Management Materials for EVs: Four top trends we’re seeing in the market for 2021 when it comes to thermal management solutions.
  • Insights, data and real-world testing will be presented for the following trends-
  • Serviceability: EV Batteries need to be repaired or replaced as they age.
  • Reworkability: Addressing challenges during repair, removal and re-manufacturing.
  • Low Density Materials: Materials with high thermal conductivity traditionally are very dense, but with the increasing need for light-weighting in the automotive market, thermal management suppliers are finding ways to maintain thermal conductivity while reducing density.
  • Alternate Chemistry Materials: Silicone versus Non-Silicone

TUE-11-MAY 11.00am (CET)

Liquid Cooling For EVs – Cooling Strategies & Avoiding Issues For Reliable Fast Charging

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Beth Langer, R&D Engineering Manager, CPC

Speaker Biography | Company Profile

  • Exploring Different Cooling Strategies For Fast Charging And High Performance Electric Vehicles

TUE-11-MAY 13.00pm (CET)

Integration Of The Battery Casing With The Cooling Plate, Enabled By A Coolant-Resistant Structural Adhesive

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Peter Cate, Global Automotive Strategist, L&L Products

Dagmar van Heur, Global Strategic Marketing, Commercial Transportation, L&L Products

Speaker Biographies | Company Profile

L&L Products

  • Durable cooling system enabled by hot-coolant-resistant structural adhesive
  • Reduced weight versus monolithic protection covers
  • Reduced packaging space via integrated cooling channels
  • Simplified battery assembly with no separate pipework
  • Enhanced thermal efficiency between cells and cooling system

TUE-11-MAY 15.00pm (CET)

Why Is The Ultra-Thin Heating Polyimide Film The Best Value Solution For Battery Warm Up?

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Matt Hummel, Account Manager Specialist in EV Vehicles/Battery Management US, ADDEV Materials Group

Aziz Rezig, Innovation & Development Manager, ADDEV Materials Group

Speaker Biographies | Company Profile

Addev Materials

  • Ultra-Thin Heating Film DuPont™ Kapton® RS
  • An integrated heating film solution that contains a flexible electrically conductive black polyamide which is used as a base substrate. The film is a bi-layer substrate : one dielectric layer and one conductive layer. This substrate benefits from a constant resistivity which allows to be used in heater applications.
  • Low thickness
  • Increased reliability
  • Thermal homogeneity
  • Reduction of the carbon footprint

TUE-11-MAY 12.00pm (EST)

Adhesive & Sealing Systems For High-Voltage Batteries In Electric Vehicles

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Nathan Whitford, Global Product Manager, OEM & EV – HB Fuller

Speaker Biography | Company Profile

HB Fuller

  • An overview of adhesive system technology offerings for high-voltage batteries
  • Assessing desired strengths, service considerations and the manufacturing requirements
  • Further options for replacing mechanical fastenings
  • Gap fillers as suitable alterations to thermally conductive pads
  • Thermal characteristics and requirements for high voltage batteries

WED-12-MAY 11.00am (CET)

Thermal Interface Materials – Gap Filler Liquids For Battery Systems

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Kerafol/Invited TBC

  • Thermal Interface Materials – Gap Filler Liquids for Battery Systems
  • Silicones and ceramic fillers – adjusting screws for mechanical, thermal and electrical properties
  • Thermal Interface Materials (TIM)
  • Ensuring Reliable Thermal Management For Operational Safety in Batteries and power conversions
  • Thermal Transfer at Batteries
  • Benefits of Gap Filler Liquids for Batteries
  • Cost-Efficient Processes And Technologies Allowing High-Speed Assembly Of Cells

WED-12-MAY 13.00pm (CET)

Understanding The Thermal And Safety Challenges In Next-Generation Battery Packs

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Bret A. Trimmer, Applications Engineering Manager – Neograf Solutions

Jon Taylor, Product Manager – Neograf Solutions

Speaker Biographies | Company Profile

Neograf Solutions

  • There are four main strategies battery pack manufacturers use to prevent propagation. Each method will be discussed.
  • Each method introduces benefits or harm to the cells in terms of fast charging ability, cell cycle lifetime, maximum discharge rate, and driving range.
  • For applications where smaller-pack-size and lighter-weight are important, flexible graphite is used as a direct substitute for aluminum

WED-12-MAY 15.00pm (CET)

Innovations In Electric Vehicle Cooling Technologies

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Brian Costello, Advanced Development Engineer, Senior Flexonics

Company Profile

senior-flexonics

WED-12-MAY 12.00pm (EST)

Robust Early Detection Of Thermal Runaway (REDTR)

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Amphenol/Invited TBC

  • New sensor technology to detect thermal runaway
  • Stressed Li-ion batteries can undergo failure through a variety of factors. Failure can result in an internal reaction that generates heat and causes chemical decomposition of the cell, which can rapidly accelerate into thermal runaway
  • How to quickly identify initial cell vent – fast detection enables rapid countermeasures

THURS-13-MAY 11.00am (CET)

Fast Charging And Batteries of The Future: What Will Be The Impact of Fast Charging On Battery Thermal Management

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  • Ultra-capacitors and their role in future powertrains: Increased power density for enhanced vehicle performance and reduced battery size
  • New battery materials and design for greater energy density and efficiency
  • Solid state batteries and their commercialisation
  • Lithium-ion innovation
  • Developing a battery that operates optimally across a wider range of temperatures
  • Battery packing: Thermal dissipation materials for assembling the battery

THURS-13-MAY 13.00pm (CET)

Dealing With Thermal Runaway

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  • Introduction of the thermal runaway and propagation
  • Review thermal runaway mechanisms and trigger methods
  • Existing and pending regulations related to thermal runaway propagation
  • Discussion on various approaches to dealing with thermal runaway

THURS-13-MAY 15.00pm (CET)

Simulation To Aid Design: Accurately Predicting Thermal Performance And State of Health of A Battery Pack

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AVL / Invited TBC

  • Battery Lifecycle Management To Improve Battery Value And Profitability
  • Battery Degradation Minimization By Thermal Management,
  • Operation And Charging Strategy Optimization
  • Thermal, Electrical And Mechanical Effects On Battery Ageing
  • Real-Time Battery Electric Vehicle Fleet Data Collection In The Field
  • Battery Ageing Testing, Modelling And Lifetime Prediction
  • Customized Fleet Analytics Platform And Fleet Recommendation

THURS-13-MAY 12.00pm (EST)

Cell & Battery Abuse: Development Of Thermal Runaway/Propagation Tests For EV & Stationary Batteries

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Rich Byczek, Global Technical Lead for Electric Vehicle and Energy Storage, Intertek

Speaker Biography | Company Profile

intertek

  • Understand the key regulatory and standards roadmaps for EV, Stationary and eMobility battery applications
  • Thermal runaway and propagation occurrences in the real world
  • Key Thermal runaway test requirements and standards
  • Methods of inducing single cell events in the lab environment
  • Scaling to module and system tests
  • Test criteria, data collection and measurement methods
  • Limitations and challenges in test environments

FRIDAY-14-MAY 11.00am (CET)

Single-Phase Immersion Cooling For Thermal Management Of Lithium-ion Batteries

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  • Immersive cooling system versus contemporary cold-plate cooling methods
  • Investigating the difference in performance between immersive and cold plate cooling systems

FRIDAY-14-MAY 13.00pm (CET)

Thermal Interface Materials For Electric Vehicle Battery Packs

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FRIDAY-14-MAY 15.00pm (CET)

Analysis And Modelling Of The Vehicle Thermal Management System For BEV’s

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  • Can battery test simulation solve the thermal challenges of electric vehicle fast charging?
  • Battery simulation and correlation to enhance battery thermal management in a fast charging scenario

FRIDAY-14-MAY 12.00pm (EST)

Effective Temperature Management of BEV, NTC Thermistors

RECENT BATTERY THERMAL MANAGEMENT WEBINAR SESSIONS

Overcoming Technical & Cost Challenges For Next Generation Automotive Batteries

Adhesive And Sealing Systems For High-Voltage Batteries In Electric Vehicles

Understanding The Thermal And Safety Challenges In Next-Generation Battery Packs

lubrizol-fev

Why Immersed Battery Cooling

Monitoring Cell Temperature To Optimize Battery Performance And Design

Extending Battery Life of Electric Vehicle Fleets

Silicone Foams And Thermally Conductive Silicones In Battery Pack Assembly

Simulation To Aid Design: Accurately Predicting Thermal Performance And State Of Health Of A Battery Pack

Methodology For Modelling And Simulating Battery Thermal Runaway Events

Thermal Interface Materials – Gap Filler Liquids For Battery Systems

Henkel

Specifying Thermal Management Solutions For Battery Pack Design

AUTONEUM

Battery Thermal Comfort: A Multi-Component Approach

If your company is interesting in hosting or sponsoring a webinar or virtual workshop as part of this years Battery Thermal Management Innovation Webinar Series please reach out to us

info@we-automotive.com USA +1 (313) 799 2911 or Europe +44 (0)7932 631 029

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