EV packages are accelerating at an unprecedented tempo as automotive OEMs race to realize their electrification targets. Subsequent-generation battery platforms are fueled by innovation, however this new expertise requires engineers to be taught on the job whereas concurrently designing their packs. Gaps in understanding an element’s efficiency can result in engineering change requests (ECRs) and delay manufacturing.
Passenger and business car OEMs in Asia, Europe, and North America accomplice with Aspen Aerogels to unravel thermal runaway propagation challenges. Thermal barrier packages usually expertise ECRs as a result of pack-level thermal propagation conduct turns into obvious late within the design cycle. Cell-to-cell limitations are the simplest half to change when points with meeting, cell-face strain, and cell efficiency come up. Aspen’s in depth information of aerogel expertise and the complexities of thermal runaway has helped OEMs obtain their security objectives and preserve tight deadlines.
PyroThin is an aerogel cell barrier that may act each as a thermal barrier and compression pad in a single materials. Understanding the lifetime mechanical efficiency of a cell barrier is essential as a result of it impacts the pack’s security and efficiency. Li-ion pouch and prismatic cells have preferences concerning the cell-face strain they need to be held, which varies by producer. For instance, some cells desire a tight embrace, whereas others desire featherlight contact. Discovering the right stability is essential as a result of mechanical conduct influences the state of well being.
Cell-face strain evolves as cells breathe throughout cost and discharge cycles, in addition to swell as they age. Over time, cell limitations are additionally compressed to a fraction of their unique thickness as they’re squeezed between the shifting cells. Predicting that evolution is essential to understanding end-of-warranty and end-of-life battery efficiency. Incorrectly managing mechanical conduct can result in untimely cell degradation, resulting in costly guarantee claims or recollects.
Fatigue biking to check mechanical efficiency doesn’t present a full image. Prescribed displacement permits engineers to regulate strain however not pressure, whereas the alternative is true when setting load parameters. Cell-face strain evolves over time as cells increase and cell limitations fatigue. Engineers should additionally think about different elements inside the pack, comparable to finish plates, cell-to-end limitations, and different elastic parts.
Aspen designed a extra sensible take a look at setup to guage cell barrier lifecycle fatigue. If engineers can not acquire utterly discharged li-ion cells, a surrogate cell will be product of low-density polyethylene (LDPE). To calculate the cell stiffness, take the cell’s modulus and divide it by the thickness. This can inform the required thickness of LDPE. Different inputs required for this take a look at embody geometry, compressive moduli, beginning-of-life strain, swelling and respiration percentages, and variety of cycles.
Earlier than testing, create a compression pressure deflection (CFD) curve for every pattern and calculate the typical. In Aspen’s checks, 1.7mm PyroThin was positioned onto a metal plate above the LDPE block. PyroThin cell barrier samples underwent 1400 cycles to simulate the end-of-life situation of an NMC cell. A brand new CFD curve was then measured, which included the results of fatigue set. The trail between cycle 1 and 1400 was proven to behave logarithmically, enabling engineers to foretell PyroThin’s evolution as a operate of cycle depend. Having PyroThin’s anticipated thickness provides engineers perception into PyroThin’s anticipated thermal and mechanical efficiency all through the pack’s lifetime.
Aspen Aerogels has a devoted in-house mechanical testing lab that automotive OEMs can make the most of as an extension of their testing capabilities. Contact their technical crew to be taught extra about higher predicting the lifetime efficiency of cell limitations.
