In an business shifting 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 as a result of 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 obstacles, cushioning foams, sealants, and extra, the worldwide firm is addressing essential points corresponding to thermal administration, battery pack meeting, price discount, and manufacturing effectivity.
One of the urgent issues in Li-ion battery programs is thermal runaway. To assist handle this design problem, the corporate provides 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 preserve 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 following. And each sequence could be utilized between cells to assist cut back thermal transport in excessive temperatures.”
Rohmann explains {that a} key problem in battery pack meeting is sustaining constant strain throughout the battery whereas absorbing mechanical stresses and vibrations. 3M Cell Enlargement Foam SJCEF is a flame-retardant microcellular polyurethane foam that meets this want. Its self-tacky properties cut 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 suggests the fabric can accommodate a number of battery designs with out compromising efficiency,” making it very best for each EV and hybrid purposes.
Battery enclosures have to be sealed to forestall moisture ingress, shield inside parts, 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 getting old 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 position in sustaining long-term battery pack integrity in various environmental circumstances.
In accordance with Rohmann, product improvement within the battery sector is something however static. Certainly, OEMs are regularly refining their designs to satisfy shifting efficiency, price, and security targets. She feedback, “The client develops and optimizes their battery designs very dynamically in response to consistently altering challenges from the business. This could generally be very short-term. Our expertise is essential in anticipating sure materials properties or incorporating them prematurely.” This fast 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 speak via technical challenges allows everybody to grasp the place the ache factors are. Generally these are within the product idea, generally in the way to combine an revolutionary thought into the manufacturing course of. Via shut collaboration, each events have the chance to be taught concerning the feasibility, improvement potential, and limitations of one another.”
Certainly, it’s right here when an OEM’s challenges grow to be 3M’s challenges. “A major concern of OEMs is price discount,” she says, including, “Decreasing the price of battery packs to make electrical autos and different purposes extra reasonably priced is a significant problem.” This, she reveals, entails optimizing manufacturing processes and materials utilization, as effectively balancing efficiency with materials and manufacturing prices.
After which there are challenges related to thermal administration. As vitality density will increase, so does the problem of better warmth launch. “Effectively managing the warmth generated to handle 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 handle this.
Whereas early battery pack designs targeted on single-purpose supplies, over time the business has shifted to multi-purpose supplies, as Rohmann explains, “With better concentrate on car affordability and industrialization, OEMs are searching for options that not solely meet the appliance objectives, however achieve this in a manner that may be simply built-in into their manufacturing processes.” She reveals that OEMs are additionally searching for materials options that assist handle a number of necessities distinctive to the brand new chemistry and type components which can be in the marketplace.
“Within the case of thermal runaway obstacles, because of this the necessities for the chosen supplies nonetheless want to stay extraordinarily excessive when it comes to thermal stability, however they need to now additionally supply 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 plain that security and environmental laws are additionally shaping product improvement, as Rohmann feedback, “Rules for EVs and thermal occasions are designed to assist handle 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 using supplies that may assist with disassembly and recycling. These components are included into the corporate’s R&D plans to take care of future-ready options.
Whereas EV and hybrid battery packs face totally different challenges, corresponding to vitality density for EVs and ICE integration for hybrids, many options could be shared or complementary between platforms. Advances in battery expertise, thermal administration, and management programs for one sort can typically be tailored for the opposite,” says Rohmann “and enhancements in manufacturing effectivity and value discount methods can profit each full EVs and hybrids.”
This cross-pollination of concepts and applied sciences is what’s going to allow strong, versatile options which can be able to addressing the complete spectrum of EV necessities. “By addressing these challenges with revolutionary options and leveraging synergies between full EV and hybrid applied sciences, we will improve the efficiency and competitiveness of each forms of autos,” Rohmann concludes.
