• How to improve thermal efficiency, enhance lightweighting & integrational capacity of components and further advance BMS capacity

• Utilizing new design techniques, resistance to fire materials & emerging tools for reduced safety and thermal runaway risk

• Battery pack integration & thermal optimization at the system level

• Battery Thermal Management: Trends in electric vehicles

• Examining where we stand now and what challenges remain: Future outlook and possible technological solutions in development.

• How can an optimal thermal management system strategy be developed and what are the next-generation objectives?

• Assessing current technologies and methods for thermal conductivity and inclusion technology.

• Implementing thermal management to optimize battery life.

• How to effectively measure and evaluate thermal management solutions.

• The role of material science in thermal management.

• How close are we to consolidating an industry-standard in thermal management architecture?

• Exploring the various design trends and engineering challenges driving interest in new and effective bonding solutions for EV battery pack materials.

• Defining the advantages of high-performance tapes featuring pressure-sensitive adhesives: Effective bonding, but also to help address issues related to flame retardancy, boosting dielectric, and optimizing design and assembly.

• This session will showcase the benefits of pressure sensitive adhesive technology. Exploring this solution for a wide range of pack applications

• How to achieve “Robust Early Detection of Thermal Runaway” in Lithium-ion battery technology.

• Learn of the physics and chemistry of battery failure, the hazards of damaged battery systems, and the means of reliably detecting the moment a damaged battery cell vents.

• Attendees will learn of the latest trends in xEV, EVSE, and ESS thermal system design as well as design features necessary for durable and accurate measurement and control of thermal management systems, including immersion cooling and heat pump type systems.

• Presentation will review and address needs for critical sensing points within typical systems as well as environmental and communications constraints that drive design choices.

• Examining the five factors that allow cells to charge quickly and discussing the single factor that pack designers can control.

• Exploring the four primary strategies pack manufacturers use to prevent Thermal Runaway and the impact of each on fast charging, cell performance and lifetime.

• Look at each propagation control method: Benefits or harm to the cells in terms of fast charging, cell cycle lifetime, charge rate, and driving range.

Garrett Hutchinson, Vice President, Engineering at Poly-Nova Technologies

• A fast-curing, structural seal that will remain stable and reliable under high thermal stress, for electronics applications.

• Multiple curing temperatures that provide the flexibility customers need in their operations.

• Fast cure at low temperature, with fast adhesion build-up.

• The key considerations when designing inter-cell battery packaging: battery performance, thermal runaway delay and reducing wasted space in the overall pack design

• Intrinsic material properties critical for cell-to-cell pressure management and validation through single cell application testing

• Review mechanisms to delay thermal propagation, material level test methods and single cell application test

• Selecting dual function battery pads maximize cell performance and safety while minimizing process steps and cost

Dr.-Ing. André Schlott, Head of Competence Center
Energy and Thermal Management – Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM

• What is needed to develop a suitable cooling solution – from requirements to a tested prototype

• Cooling power electronics with different media (fluids)

• Considerations to reduce thermal resistances

• How to reduce hotspot temperatures with a proper material selection

• Introduction into Virtual Battery Development

• Discussion of modeling approach managing different scales and domains

• Electrical and Thermal Modelling at Cell/Module/Pack Level

• Model characterization and validation

• Impact of thermal regulation on battery performance/degradation

• Mitigating thermal runaway heating and arresting flames using KULR’s Thermal Runaway Shield (TRS).

• Test and analysis results for battery pack with and without TRS.

• Addressing Lithium-ion cell/battery transportation concerns with KULR’s innovative solutions.

• Thermal interface materials that keep cells at preferred temperatures during both charging and operation

• Thermally conductive adhesives that help enable faster charging while providing higher strength in pouch cell and cell-to-pack designs

• Tailored-design of high strength, high elastic, and breathable adhesives that hold and protect battery cells for their entire service life

• Structural and crash durable adhesives for improved battery pack strength and durability

• How TIM-s can enable reliable battery pack thermal management and protect against thermal propogation

• How innovative sealant technologies can optimize battery pack serviceability and provide reliable shield against external contaminants

• How adhesives can unlock cost-efficient, high-speed and flexible component assembly

• Achieving high BEV charge rates is a complex interrelated multi-dimensional problem.

• High battery charge rates result in heat from atomic charge transfer at the cell, pack and system levels. Increasing battery charging current increases the need for cooling, as well as heating, and puts more of a premium on waste heat recovery to condition the battery.

• The thermal characteristics of battery cells are the core challenge

• Examining the latest developments in fast charging and the impact on battery thermal management.

Charging challenges: Overcoming the most significant barriers to market growth, analysing the standards, technological and infrastructural challenges in fast and ultra-fast charging.

Improving Energy Density And Performance Of EV Battery Packs With Thermal Management And Coatings

• Identifying the wide range of needs related to battery pack insulation, battery pack assembly, component assembly, gap filling, power control unites and cables/connectors

• Effective thermal management within the battery pack and across the powertrain components

• Tuning materials to provide thermal insulation or thermal conductance within the base silicone foam, adhesive, elastomer, potting compound or paste

• A customised approach to battery interstital fill, thermal interface, adhesives, potting and protective covering material – to meet design specification

• Selected material and design examples

Battery Management Systems (BMS) And The Need For Efficient Control And Monitoring Of An Integrated Battery System

• Various solutions and pack designs

• Combination of gap-filler and fixation/cast and forget approach

• High flexibility over the whole operating temperature

• Green and clean resins for environmental and health safety

• Homogenous heat dissipation through fine-tuned thermal conductivity

• Outgassing free formulation/no Silicones

• Excellent thermal shock behavior

• Non-flammable and self extinguishing

Chairs Closing Remarks