Battery Module Assembly Materials

Share on linkedin
Share on twitter

Table of Contents

Modeling of Battery Module Assembly Materials For Design and Safety Considerations

In this post you are going to learn everything related to Dowsil’s Battery Module Assembly Materials. Read the information below.

Battery Thermal Management Gap Fillers

  • Battery modules require soft compressible thermally conductive materials to dissipate heat and relieve mechanical stressBattery Module Assembly Materials 
  • Typical requirements:
    • Thermally conductive: 1-5W/m·K
    • Vibration dampening: material has to remain flexible
    • Non-flammable
    • Non-flowable but filling complex geometries when compressed (spreading behavior)
    • Low volatiles <100-300ppm
    • (Generally) electrically insulative
    • (Generally) removable adhesion for repairing/recycling

Thermal Stress Modeling Example

  • Objective: Understand the impact of thermal conductivity of thermally conductive gap fillers on the thermal and stress fields in a battery module during normal battery operations
  • Approach: Sequentially coupled thermal-stress analysis of a representative model

 

Battery Module Assembly Materials

 

Thermal Model Example

 

 

  • Steady-state heat transfer initial temperature: 24 ºC.
  • Thermal loads volumetric heat generation rate: 9,560.5 W/m³
  • Boundary conditions:
    • Forced liquid cooling channel: coefficient 30W/m²K
    • Exposed surfaces: convective heat transfer coefficient of 4 W/m²K
    • Film temperature: 24°C

 

Stress Model Example

 

Battery Module Assembly Materials

  • Loads: non-uniform temperature field from the thermal model analysis
  • Boundary conditions: top surface of the top gap filler panel and bottom surface of the bottom gap filler panel were constrained
  • Gap filler material model: hyperelastic

 

Gap Filler Thermal Conductivity Affects Temperature Distribution

 

Battery Module Assembly Materials

 

Higher Thermal Conductivity, Lower T??? AND ∆T

The thermal model suggests using gap fillers with higher thermal conductivity can:

  • Reduce peak temperature – lower thermal runaway risk
  • Keep battery operating in optimal working temperature range
  • Increase battery performance (e.g. charge/discharge rate, driving range)
  • Significantly improve temperature uniformity

 

 

Lower ∆T, Lower Thermal Expansion

 

Battery Module Assembly Materials

 

Thermal Strain Leads To Mechanical Strain/Stress in Battery

 

Battery Module Assembly Materials

 

Strain Relief in Insulation Pad

More uniform temperature, lower strain and stress, higher reliability

 

Stress Reduction on Battery Cell

 

Battery Module Assembly Materials

 

Summary of Stress Analysis

Model suggests that using gap fillers with higher thermal conductivity can:

  • Lower stress amplitude and concentration
  • Minimize premature material failure
  • Improve safety and reliability

 

 

Conclusions

  • A thermal-stress model was developed to gain insight into the thermal and stress fields during normal battery operations
  • The model suggests multiple benefits of gap fillers with higher thermal conductivity
  • Integrated modeling enables
    • Materials selection and development based on customer requirements
    • Optimization of system performance and manufacturing process
    • Reduction of product development cycles
  • Future Work
    • Enhance model to account for interfacial thermal resistance
    • Model customer-specific design configurations

 

Portfolio Of Advanced Thermally Conductive Materials

 

Battery Module Assembly Materials

 

We are your technical partner.

If you have any questions or want to find out more about the possibilities for your industrial application, please complete the contact form and one of our experts will be in touch.

If you have a problem with industrial adhesives, sealants, lubricants or electronic protection products and require advice, you can contact our technical support service. Our team can help you to optimize your processes and applications.

Share this post

Share on linkedin
Share on twitter

Subscribe to our News & Updates

Related Posts

what is wear
What is wear and how to prevent it?

Tribology is the science that studies friction, wear, and lubrication of touching surfaces in relative motion. It relies on concepts coming from materials science, physics, and chemistry among others, making

Read More »
5 ways to optimize your engine’s performance

Modern cars draw more power and performance from smaller engines, but they also need to make sure passengers have a comfortable, quiet ride. So basically, what’s needed is an extreme performance in materials for extreme conditions. But how can you ensure your engine is running at its absolute optimum, all the time?

Read More »

Can't find the right product?

Talk to a Technical Representative