• How to improve thermal efficiency, enhance lightweighting & integrational capacity of components and further advance BMS capacity

• Utilizing new design techniques, resistance to fire materials & emerging tools for reduced safety and thermal runaway risk

• Battery pack integration & thermal optimization at the system level

• Battery Thermal Management: Trends in electric vehicles.

• Examining where we stand now and what challenges remain: Future outlook and possible technological solutions in development.

• How can an optimal thermal management system strategy be developed and what are the next-generation objectives?

• Assessing current technologies and methods for thermal conductivity and inclusion technology.

• Implementing thermal management to optimize battery life.

• How to effectively measure and evaluate thermal management solutions.

• The role of material science in thermal management.

• How close are we to consolidating an industry-standard in thermal management architecture?

• Various design trends and engineering challenges are driving interest in new and effective bonding solutions for EV battery pack materials.

• These solutions include high-performance tapes featuring pressure-sensitive adhesives. Such tapes provide not only effective bonding, but help address issues related to flame retardancy, boosting dielectric, and optimizing design and assembly.

• In this session, Scott Krusinski, Avery Dennison Performance Tapes product manager for Automotive & other Transportation, will showcase the benefits of pressure-sensitive adhesive technology. He’ll discuss why it’s a sound solution for a wide range of pack applications and provide an overview of Avery Dennison’s capabilities related to EV batteries.

• Air cooling is neither safe nor effective and this session will demonstrate the immediate advantages of SLIC technology as the superior solution

• Examining the drivers for immersion cooling

• Outlining the cooling fluid requirements for immersion cooling

• Examining the drivers for immersion cooling

• What is a Single-Phase, Liquid Immersion Cooling?

• Exploring coolants compatibility with materials used in Battery Management Systems

• Demonstration of how immersion Cooling with AmpCool extends battery life

• How to prevent fire propagation between battery cells using AmpCool Coolant

• A fast-curing, structural seal that will remain stable and reliable under high thermal stress, for electronics applications.

• Multiple curing temperatures provide the flexibility customers need in their operations.

• Fast cure at low temperature, with fast adhesion build-up.

• Various solutions for cylindrical/ prismatic/ pouch cell modules and pack designs

• Combination of gap-filler and fixation / cast and forget approach

• High flexibility over the whole operating temperature

• Green and clean resins for environmental and health safety

• Homogenous heat dissipation through finetuned thermal conductivity

• Outgassing free formulation / no Silicones

• Excellent thermal shock behavior

• Non flammable and self extinguishing

• This disruptive, holistic thermal management solution effectively addresses the significant challenges of cooling and heating the entire automotive battery system, powertrain, compute, and electronic components. The technology is based on two-phase immersion pool boiling for extremely efficient active control.

  Our two-phase immersion TMS technology enables:

  – Keeping battery cells at the optimal temperature

  – Ensuring uniform temperature for the entire pack down to the cell level

  – Indifference to ambient temperature

  – 3X higher in-vehicle heat dissipation capacity

  Delivering benefits

  – Extending battery lifetime and warranty opportunity

  – Delay and even prevent thermal runaway

  – Makes battery charging possible at 10C+

  – Same battery cell chemistry everywhere in the world

  – Reducing the total cost of ownership for OEMs, dealers, and consumers

  – Perfect for extreme and prolonged acceleration for high performance

  – Growing the second-hand EV market

• Mitigating thermal runaway heating and arresting flames using KULR’s Thermal Runaway Shield (TRS).

• Test and analysis results for battery pack with and without TRS.

• Addressing lithium-ion cell/battery transportation concerns with KULR’s innovative solutions.

• Reviewing the latest goals and best current methods for EV battery thermal management.

• Examining the five factors that allow cells to charge quickly and discussing the single factor that pack designers can control.

• Exploring the four primary strategies pack manufacturers use to prevent Thermal Runaway and the impact of each on fast charging, cell performance, and lifetime.

• Each propagation control method introduces benefits or harm to the cells in terms of fast charging, cell cycle lifetime, charge rate, and driving range.

• Understanding the three key advantages that graphite offers for thermal management.

• For applications where smaller-pack-size and lighter-weight are important, flexible graphite will be discussed as a direct substitute for aluminum.

• Preventing thermal propagation starts with the cell-to-cell (C2C) barrier.

• Aspen Aerogels’ PyroThin materials are widely recognized as providing the highest thermal performance in the industry, and recent testing is beginning to reveal why.

• The surprising interactions between compressive loading and thermal behaviour are leading to some of the most space- and weight-efficient solutions available today.

• Introduction into Virtual Battery Development

• Discussion of modeling approach managing different scales and domains

• Electrical and Thermal Modelling at Cell/Module/Pack Level

• Model characterization and validation

• Impact of thermal regulation on battery performance/degradation

• The safety level of lithium-ion batteries depends not only on the cell-to-cell chemistry but also on the protection of connections around the battery modules, making thermal management activities a key process for EV manufacturers.

• Analyzing high-performance solutions that are inherently flame resistant and more resilient to continuous high temperatures.

• This presentation will explore the key considerations to designing inter-cell battery packaging: battery performance, thermal runaway delay and reducing wasted space in the overall pack design

• Intrinsic material properties critical for cell-to-cell pressure management and validation through single cell application testing

• Review mechanisms to delay thermal propagation, material level test methods and single cell application test

• Selecting dual function battery pads maximize cell performance and safety while minimizing process steps and cost

• H.B. Fuller Supports EV OEMs and Tier manufactures by providing innovative materials, battery safety solutions, thermally conductive products, structural adhesives and sealing technologies. We provide complete turnkey solutions by including chemistry selection, product validation, production implementation, and technical support throughout the entire commercialization process.

• Our patented EV Protect 4006 increases EV battery safety by improving protection against fires and thermal propagation. Additional key benefits include corrosion protection, semi-structural support, NVH properties, impact resistance, while helping to maintain a stable internal battery temperature from extreme external environments.

• H.B. Fuller’s next generation innovative adhesive and sealant solutions provide improved thermal management performance, increase structural rigidity, and seal against external environments. We are dedicated to developing products that help provide a safer battery for the future.

• The manufacturing processes for batteries and where our technologies can be applied;

• Challenges of dispensing of thermal materials, volume shot sizes, etc.

• The importance of surface pre-treatment in come applications

• Heat staking and the need to have good process control to achieve consistency and strong rivets.

• The benefits in high-temperature design for safety

• The benefits in high-temperature design for battery lifetime

• The benefits in high-temperature design for fast charging

• The benefits in high-temperature cell design for battery pack design

• Using thermally modulated cells to simplify high-temperature operation logistics

Chairs Summary

• Overview of the key industrial challenges discussed during the day

• Summary of the various technologies and technological areas covered

• Highlighting of any further topics, innovations or conversations that can be progressed

• The safety, reliability and durability of battery electric vehicles relies in large part on what holds the vehicle and its battery assembly together – namely, adhesives. You will hear about:

• How adhesive technology enhances ride and handling performance, NVH, and crash resistance – while reducing mass that helps extend range

• Creating designs that use fewer components and reduce assembly complexity

• Multifunctional benefits of adhesives including structural attachment of battery components and effective thermal management during vehicle charging and operation

• Adhesive technology that helps advance high voltage cell-to-pack and cell-to-vehicle designs

• Important adhesive chemistries that are enabling automakers worldwide to achieve benefits resulting in cost-effective production and higher performance of battery electric vehicles that are safe, reliable, and durable

• Summary and overview of >30 laser applications established in the Lithium-ion battery mass manufacturing process

• Highlights of a few advanced laser processes:

• Green laser for battery foil stack welding

• Spatter-free busbar welding with BrightLine Weld

• Die-cast aluminum welding with Multi-focus optics

• Laser cleaning for enhanced adhesive bonding for battery pack

• Outlook of emerging laser applications for future Lithium-ion battery manufacturing process

• Integration of traditional spring elements into one component, creating a built-in “clamp load sensor” that enables for immediate controllable clamp load for known input torque

• Higher clamp load retention after being subject to thermal and dynamic loads

• Creates permanent electrical contact in joints with low surface pressures

Digital Twin Benchmarking Using High Energy Technology For Battery Innovation And Delta Costing

• Polyurethane Composites – When The Sum Is Greater Than Its Parts

• BASF Performance Materials Technology Summary

• PUR composites in diverse automotive applications

• PUR + fiberglass pultrusion introduction and technology overview

• Performance vs metal/other materials, thermal performance

• Development with L&L Products

• Ford Lightning’s success story

One Step Joining For Reliable Electrical Components: Cell-to-Cell With E-Clinching

An overview of the Dassault Systèmes battery modeling capabilities from atoms to system. Focus in this presentation is placed on 3D modeling aspects from parametrized designs to engineering KPIs:

• 3D Cell engineering including thermo-electrochemistry in charge/discharge applications and associated swelling, short circuit and thermal runaway

• Module/Pack Engineering focusing on durability, thermal management, and safety applications

The 3DEXPERIENCE platform can be used to facilitate collaboration across entire organizations and functions. In this example, we will demonstrate how the 3DEXPERIENCE platform can be used to facilitate the design an e-drive motor from requirements and test planning to conceptual design, and all the way to detailed design and performance analysis.

• Vehicle End of Life, and Lithium Ion battery disposal recycling concerns remain an ongoing concern for the industry. Lack of harmonized designs and physical battery construction continue to present challenges in recycling or harvesting of modules and cells.

• Re-purposing of entire battery packs, as-is, maybe a promising option, but some challenges remain.

• The Sorting process, labelling, and demonstrating compliance for Stationary Energy storage or other non-EV applications will drive a new compliance plan.

• This talk reviews the current status and highlights from the ANSI/UL/CAN 1974 standard and how it relates to repurposing of EV batteries.

The Future Of Low Voltage Batteries For An Electrified Future

• Learn how to leverage battery data to bring products to market faster

• Introduction to common battery analyses and the Voltaiq tools that speed up these analysis workflows by 20,000x

• How to ensure your battery supply is high quality and minimize battery product risks

• How to provide visibility into manufacturing operations and confirm quality metrics are fully met

• How to integrate the leading data science and machine learning tools into a battery development program

Conference Closing Remarks