Electric Vehicle (EV) Battery Packaging

Electric Vehicle (EV) Battery Packaging: Thermal, Electrical, Mechanical and Safety Considerations for

Manufacturability Reliability Recyclability

Battery assembly is critical for the powering, reliability, and safety of Electric vehicles (EVs). The packaging and packing from individual cells in the shape of a cylindrical, pouch, and prismatic into final assembly requires the use of different potting, adhesive, and thermal interface pads, to provide the mechanical and thermal interface to achieve reliability and safety.

With the weight and volume of battery usages, the disposal of the battery assemblies after its life cycles, ability to recycle the metallic materials used in the battery assembly is also becoming critical and integral consideration.

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Unit battery cells from cylindrical, pouch, and prismatic packing into the required high voltage and power EV Battery require different thermal, electrical, and mechanical interfaces along with safety and recycling considerations.

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Battery assembly from cells to modules and final assembly requires electrical interconnection and insulation, fire-retardant in safety provision, and thermal interfacing to the cooling system, and mechanical interfacing to the vehicle structure and frame. In the life cycle of the EV battery, the ease of recycling is also a critical and integral part of the design consideration.

Gap-Filling Thermal Gel for EV Battery Module Packing

Gap-Filling Compressible Non-Curing Pad Module to Cooling System Interfacing

Other Thermal, Electrical, and Mechanical Interfacing Material Solutions for EV Automotive Applications

Gapfillthermalgel (2)

Long pot-life (floor working time) for ease in manufacturing operation
Form stress-free gel at ambient to ensure long-term reliability
High thermal conductivity for hot-spot prevention and low thermal resistance interface to the module case housing
Intrinsically fire self-extinguishing (UL 94V-0) for vehicle safety
Ease of rework and end-of-life recycling for long-term viability

Gapfillcompressible

Thermal pad with outstanding compressibility for ease of pick-and-place manufacturing operation
Non-curing stress-free mechanical coupling to the cooling system
High thermal conductivity with low thermal resistance interface to the cooling system structure
Intrinsically fire self-extinguishing (UL 94V-0) for vehicle safety
Ease of rework and end-of-life recycling for long-term viability

otherEVsolutions (2)

World’s 1^st Electrically conductive greases (ELECTRO-GREASE™)
World’s 1^st conformal coating proven for sulfur, UV, and corrosion protection (FLUOROSEAL®)
World’s 1^st and patented compressible phase-change thermal pad (COOL-PAD™)
Comprehensive PSA, film and paste thermal adhesives; non-migrating and drying thermal greases and gels; phase-change and non-phase-change pads; UV, moisture, and corrosion prevention coatings and over-coatings

What distinguishes AIT Electric Vehicle (EV) Battery Pack and Cooling System Interfacing solutions?

In meeting the challenges of EV battery pack and cooling system interfacing, AIT solutions engineered its materials to provide the manufacturers the following distinctive capabilities:

Ease in dispensing and long work life for the liquid potting thermal gel forming (to prevent drying or pumped out) compound for reliable module thermal encapsulation
Ease of placement and compressibility of thermal interface pad between modules and cooling and structural support system
Built in halogen-free UL-94V-0 fire self-extinguishing for both the potting thermal gel and compressible thermal pad
For long-term viability, AIT battery packing and cooling interface solutions are designed for ease of recycling with stress-free mechanical interfacing.

In addition to unparalleled and proven low thermal resistance, AIT’s potting thermal gel and module mounting and heat-sink thermal interfaces offer long-term reliability and consistent performance for years of thermal shock and cycling. AIT products have built-in stress relief and molecular structures that are engineered to prevent “drying” or cracking inside the materials and along the interface surfaces. Additional features include:

Ultra-low thermal resistance between cells to the casing in the module potting with thermal gel and flexibility to produce stress-free and heat-dissipating modules. These low thermal resistance gels and cured in-situ and free from drying are pumped out.
For the module to cooling system mounting, molecular flexibility is specifically engineered in the thermal adhesive to provide stress absorption even in the most mismatched CTE substrates and surfaces that extend to below -55°C. Depending on the design, AIT solutions can be customized as compressible thermal interfaced pads or pressure-sensitive adhesive pads.

All AIT solutions are designed for RoHS, REACH, and WEEE compliant besides intrinsically built-in UL94V-0 fire-retardance.