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Silicone Foam
The Role of Foam in EV Batteries. Regarding EV battery production, foam ensures optimal performance and longevity. Foam is widely used as an insulation material within battery packs, protecting the cells from extreme temperatures and vibrations. This is typically done using two component materials like silicone, silicone foam, epoxy, epoxy foam and polyurethane foam. Encapsulation foams are mixed and dispensed into a module to fill the spatial cavities between each cell.
Silicone foam for battery safety and protection
1. Top Cover
A solution that insulates the heat generated inside the battery to the outside
2. Compression Pad
Preventing thermal runaway transfer between battery cells and surface pressure during cell contraction and expansion
3. End Plate
Physical separation from surrounding battery modules and thermal runaway protection materials
4. Thermal Interface Materials
Materials that transfer heat from the battery module to the outside
How TAAK
Prevents
Thermal Runaway at every level of ev battery assemblies
Thermal Propagation for EV Battery
Studies often discuss incidents involving electrochemical cells overheating to the point of destruction or severe damage, which also harms the area around the cell. These incidents are commonly labeled as "thermal runaway." However, many research papers use this term without clearly defining it. Thermal runaway refers to a situation where there is uncontrollable self-heating. In complex systems, such as modern traction batteries that have multiple components like cells or modules, the thermal runaway in one part can affect and potentially destabilize other parts of the system. This phenomenon is known as thermal runaway propagation (TRP).
Battery Cell Solutions
1. Pouch Cells
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Pouch cells, made from flexible foil materials instead of rigid structures, reduce battery weight and offer greater design flexibility.
2. Cylindrical Cells
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Cylindrical cells consist of anodes, separators, and cathodes stacked and rolled into a cylinder-shaped container, with a single AA battery being a typical example of this structure.
3. Prismatic Cells
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Prismatic cells, constructed from layers of anodes, cathodes, and separators housed in rigid plastic or metal, differ from cylindrical cells by their stacking method rather than rolling, with many using similar compression pads and flame barrier materials for enhanced thermal runaway protection.
Battery Pack Solutions
1. Compression Pads
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Compression pads used at the module level insulate and protect individual battery modules by preventing thermal runaway propagation, reducing friction, and shielding against shock and vibration, thus localizing thermal events to prevent compromising the entire battery system.
2. Seals and Gaskets
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TAAK specializes in designing effective seals and gasketing for EV battery assemblies using optimal materials like PSAs and high-performance foams to ensure ingress protection, impact resistance, and thermal management, and offers rapid prototyping services to quickly test and validate these custom solutions.
3. Liquid Cold Plates
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Liquid cold plates in EV batteries manage heat by transferring it from the battery modules to the coolant within a cooling system, working with engineered materials like polyester dielectric tape laminated onto the plates to provide multilayered thermal runaway protection and electrical insulation, preventing issues like arcing and sparking.
Battery Pack Solutions
1. Electrical Insulators
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TAAK customizes a variety of electrically insulating materials and thermally conductive tapes to enhance battery pack safety by preventing spark voltage, isolating fires, and controlling overheating, with each design tailored to specific OEM and battery pack requirements using materials like thin film polymers and adhesives such as epoxy, polyurethane, and acrylic foam for effective assembly and thermal management.
2. Compression Pads
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Compression pads, utilized at both the cell and module levels, are integrated into battery pack structures using similar foams and materials to bolster impact resistance and thermal runaway protection while mitigating the effects of friction, mechanical movement, and swelling.
3. Seals and Gaskets
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​TAAK designs and engineers specialized gaskets and seals for EV battery housings using durable materials and performance-matched adhesives to protect against liquid, gas, and particulate intrusion, mitigate noise and vibration, and ensure reliability and performance under harsh road conditions, all while simplifying assembly and maintaining an optimal operating environment to prevent thermal runaway throughout the vehicle's life.
4. Liquid Cold Plates
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TAAK designs liquid cold plate solutions for EV battery packs that enhance thermal performance and heat transfer efficiency, featuring dielectrically insulating tapes for electrical safety and robust assembly, enabling OEMs to develop batteries with faster charging, increased power, extended range, and improved safety against thermal runaway.
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