Optimize EV Cell Performance and Pack Design with Multifunctional Materials
The renowned battery researcher Dr. John Goodenough once stated that “cost, safety, energy density, rates of charge and discharge and cycle life are critical for battery-driven cars to be more widely adopted.”
Today, for EV auto manufacturers and engineers, innovation is more essential than ever. Solutions that can provide mechanical cushioning, thermal management or insulation are top of mind, especially when it comes to balancing the safety, longevity and performance of a battery pack.
There is no doubt that robust battery packs are essential. The heavy usage, extended mileage requirements, and continuous need to safeguard against temperature, smoke, fire and water provide tough challenges at the cell, module and pack level. Furthermore, as we move beyond electrification of passenger vehicles into the electrification of medium and heavy-duty transport, mechanical cushioning and thermal runaway protection solutions are paramount.
In a Q&A interview with Dr. Fei Wang, Global R&D Manager, EV Platform at Saint-Gobain® Tape Solutions, we’ll explore some multifunctional material solutions that are dedicated to mitigating the unique challenges of the battery industry. We’ll narrow in on some recent developments for prolonging battery lifetime through mechanical cushioning and also examine progress made toward mitigating thermal runaway.
Bonus: Dive into specific case studies illustrating the durability of cell-to-cell compression foams as well as the importance of modeling technology to support customer design needs in our free, on-demand webinar with Dr. Fei Wang.
Our priority is to support customers’ success with robust and durable solutions, comprehensive testing, simulation, real-life validation capabilities, customization and co-development.”
—Dr. Fei Wang, Global R&D Manager, EV Platform
Before we dive in, could you share a little bit about yourself and more about how Saint-Gobain Tape Solutions can help customers with the development of materials for battery pack applications?
Of course. I have been with the Saint-Gobain group since 2010. My expertise lies in the development of products that could help manage cell swelling and mitigate thermal propagation.
Tape Solutions is a business unit within Saint-Gobain. Because of this, we have a strong global presence. With eight R&D centers in America, Europe, and Asia, we have the ability to provide quick and agile support to local customers. Over the years, our teams at Tape Solutions have leveraged the expertise behind our bonding, protection and insulation solutions to develop multiple materials for battery pack applications. These materials support battery packs at the cell level, with mechanical cushioning and thermal runaway protection and also at the pack level with thermal interface materials, gaskets and mechanical holding pads.
At Tape Solutions, our goal is to support our customers’ success with a wide range of robust and durable solutions, comprehensive testing, simulation and real-life validation capabilities as well as the ability to customize and co-develop materials for various battery types and industrial automation processes.
Could you share some insights about the importance of cushioning support for batteries during charge and discharge cycles?
Without a doubt, optimal compression level is critical for a battery’s longevity. It is during the charge and discharge cycles that a battery changes its dimension. This includes reversible breathing (dimensional change) of the cell as well as gradual swelling that happens throughout the lifespan of the battery.
Research has shown that optimal levels of compression are vital for maintaining the capacity of a pouch cell system and this rule also applies to the prismatic cell system, although at a different pressure level from pouch cells. The type of mechanical management solution that is required depends on cathode, anode, or electrolyte chemistry as well as case material and design.
At Tape Solutions we have polyurethane and silicone technology that allows us to customize our compression curve to specific battery needs. The tunable compression curves of these pads along with our robust simulation capabilities ensure we can support specific customer requirements and the needs of diverse battery configurations.
Products such as Norseal® PF27-250 have demonstrated remarkable stability and maintained consistent compression curves throughout 3000 cycles when subjected to evaluation of cell-to-cell compression foam using a fatigue machine under various temperature extremes.
What other tools does the Tape Solutions team have to help customers select proper compression pads for their specific design needs?
We have developed a digital tool that can provide modeling to support customer design requirements. This modeling software helps us go beyond standard testing methodologies to test and foresee potential issues and challenges that might otherwise not be accounted for. We can input a variety of data to better explore capabilities across different applications.
I dive more into this topic in a case-study of how we were able to choose between two foams to meet a special requirement for a customer in the pre-recorded webinar (link included in the introductory paragraph).
Could you share some recent developments in terms of thermal runaway propagation protection?
In terms of thermal runaway propagation protection, we are developing materials that can combine both excellent mechanical durability and effective thermal insulation. Our teams have developed new foam material with significantly lower thermal conductivity and a much higher structural integrity at thermal runaway temperature. Our Norseal TRP Series, during a thermal runaway test, effectively mitigated the propagation of thermal events to neighboring cells. The properties of the TRP product help to combine the properties of a compressible pad with thermal runaway propagation protection into one.
You can learn more about how our newest foam was able to successfully mitigate the propagation between cell one and cell two in a four-cell stack test in the pre-recorded webinar also.
As we navigate the exciting advancements in electric vehicle technology, we cannot overlook the vital importance of multifunctional materials. With comprehensive testing and innovative methodologies, our teams are dedicated to the enhancement of battery performance, longevity and, most importantly, safety. Our extensive research is reflective of our commitment to providing robust solutions, specially tailored to the unique challenges of the battery industry. For more information about our capabilities or to discuss your specific needs, please connect with our dedicated global teams today.