In an trade transferring at tempo, thermal administration, cushioning, and sealing applied sciences are redefining how battery packs are designed, assembled, and guarded.
Responding to the elevated complexity in battery pack design because of the evolution of EVs and hybrids, science-based innovator, 3M, designs and manufactures barrier supplies, cushioning supplies, and sealants.
With a portfolio that features thermal runaway limitations, cushioning foams, sealants, and extra, the worldwide firm is addressing essential points similar to thermal administration, battery pack meeting, price discount, and manufacturing effectivity.
Some of the urgent issues in Li-ion battery methods is thermal runaway. To assist tackle this design problem, the corporate presents its 3M Thermal Runaway Barrier 600/700 Sequence, which comprise a compressible, flame-resistant, thermal insulation mat materials. Able to withstanding temperatures as much as 1,200°C, these keep structural integrity even in excessive environments.
Anja Rohmann is a complicated software engineering specialist. She says, “The mat options non-classified fibers, has good flame resistance, and is designed to assist decelerate warmth switch from one cell to the subsequent. And each collection will be utilized between cells to assist scale back thermal transport in excessive temperatures.”
Rohmann explains {that a} key problem in battery pack meeting is sustaining constant strain inside the battery whereas absorbing mechanical stresses and vibrations. 3M Cell Growth Foam SJCEF is a flame-retardant microcellular polyurethane foam that meets this want. Its self-tacky properties scale back course of steps and meeting time, serving to to streamline operations. Rohmann provides, “It options customizable compression plateau for constant battery strain and is available in a variety of thicknesses, which implies the fabric can accommodate a number of battery designs with out compromising efficiency,” making it preferrred for each EV and hybrid purposes.
Battery enclosures should be sealed to forestall moisture ingress, shield inner elements, and allow future serviceability. 3M Sealant SZ1000 for EV Enclosure Sealing is a two-part, cure-in-place foam sealant designed to fulfill these buyer wants. Providing flame retardancy, wonderful ageing sturdiness, and automatic shelling out compatibility, it helps producers to satisfy strict enclosure specs whereas sustaining manufacturing throughput. Rohmann explains that whether or not utilized in EVs or hybrids, the sealant performs a essential function in sustaining long-term battery pack integrity in various environmental circumstances.
In line with Rohmann, product improvement within the battery sector is something however static. Certainly, OEMs are frequently refining their designs to satisfy shifting efficiency, price, and security targets. She feedback, “The shopper develops and optimizes their battery designs very dynamically in response to always altering challenges from the trade. This could typically be very short-term. Our expertise is essential in anticipating sure materials properties or incorporating them prematurely.” This speedy iteration cycle presents a problem for materials suppliers, however 3M is ready to stay agile with out sacrificing high quality or reliability.
3M’s method to innovation hinges on direct engineer-to-engineer collaboration; that is what the corporate refers to as ‘bench-to-bench’ improvement, upon which Rohmann expands: “Shut collaboration with the OEM is essential for the success of improvement. As soon as key alternatives are recognized, having engineers sit down and discuss by way of technical challenges permits everybody to know the place the ache factors are. Generally these are within the product idea, typically in learn how to combine an progressive concept into the manufacturing course of. Via shut collaboration, each events have the chance to study concerning the feasibility, improvement potential, and limitations of one another.”
Certainly, it’s right here when an OEM’s challenges turn out to be 3M’s challenges. “A main concern of OEMs is price discount,” she says, including, “Lowering the price of battery packs to make electrical autos and different purposes extra reasonably priced is a serious problem.” This, she reveals, includes optimizing manufacturing processes and materials utilization, as nicely balancing efficiency with materials and manufacturing prices.
After which there are challenges related to thermal administration. As power density will increase, so does the problem of better warmth launch. “Effectively managing the warmth generated to deal with security and efficiency is essential,” she displays, stating that superior supplies with excessive thermal stability and low conductivity are at present being developed by 3M to deal with this.
Whereas early battery pack designs centered on single-purpose supplies, over time the trade has shifted to multi-purpose supplies, as Rohmann explains, “With better deal with car affordability and industrialization, OEMs are in search of options that not solely meet the applying targets, however accomplish that in a approach that may be simply built-in into their manufacturing processes.” She reveals that OEMs are additionally in search of materials options that assist tackle a number of necessities distinctive to the brand new chemistry and type elements which are in the marketplace.
“Within the case of thermal runaway limitations, because of this the necessities for the chosen supplies nonetheless want to stay extraordinarily excessive by way of thermal stability, however they need to now additionally provide wonderful elasticity and prolonged sturdiness.” This nuanced stability of properties requires a deep understanding of supplies science and steady suggestions from real-world purposes, one thing which 3M is uniquely positioned to perform.
It’s simple that security and environmental rules are additionally shaping product improvement, as Rohmann feedback, “Laws for EVs and thermal occasions are designed to assist tackle security, efficiency, and environmental compliance.”
Right here, environmental mandates, such because the EU Battery Directive and Finish-of-Life Automobile Directive, are influencing designs by encouraging the usage of supplies that may assist with disassembly and recycling. These elements are integrated into the corporate’s R&D plans to take care of future-ready options.
Whereas EV and hybrid battery packs face completely different challenges, similar to power density for EVs and ICE integration for hybrids, many options will be shared or complementary between platforms. Advances in battery know-how, thermal administration, and management methods for one kind can typically be tailored for the opposite,” says Rohmann “and enhancements in manufacturing effectivity and price discount strategies can profit each full EVs and hybrids.”
This cross-pollination of concepts and applied sciences is what’s going to allow sturdy, versatile options which are able to addressing the complete spectrum of EV necessities. “By addressing these challenges with progressive options and leveraging synergies between full EV and hybrid applied sciences, we will improve the efficiency and competitiveness of each kinds of autos,” Rohmann concludes.
