from chemistry to pack
AION Engineering INC When engineering a Battery Thermal Management System (BTMS) for electric vehicles or energy storage, one of the most critical factors is hidden within the microscopic architecture of the cell itself. Whether a cell utilizes a wound (jelly roll) or stacked electrode assembly, its physical construction fundamentally dictates its thermal behavior. Heat does … Read more
When we look at the battery pack design for a vehicle we want to minimise the overall weight and hence need the cells to work structurally as part of the pack design. This leads us to Thermally Conductive Adhesives (TCAs) as a means of fixing cells to cooling systems and bonding them into a battery … Read more
What are the options for Thermal Interface Materials (TIM)? What is TIM? This is Thermal Interface Material and is designed to bridge the gap between surfaces and hence enable a better heat transfer. Thermal interface materials (TIMs) can be grouped and broken down in a few different ways, primarily by their product format (how they … Read more
A question the battery thermal team often face is: What is the Optimum Design of a Cooling Plate for Uniform Cooling? To achieve optimum uniform cooling, a cold plate must be designed to minimize temperature gradients across its surface and prevent localized hotspots. Cell to Cell Temperature Gradient The cell to cell temperature gradient in … Read more
When we consider the battery thermal management system we need to start with the basics and look at the heat sources and paths in a battery pack. We don’t have to minimise all of these sources of heat, but it is important that we carefully consider them all. It is important to calculate 1. Cell … Read more
AION Engineering INC Role of Tabs in Current Flow During discharge, the current generated by electrochemical reactions flows through the sequence: Active Material → Conductive Additive → Current Collector → Tab The tab serves as the final current-carrying element in this path. Its current-carrying capacity is therefore a critical factor that affects both electrical efficiency … Read more
In state-of-the-art indirect liquid cooling systems, temperature variations within a battery electric vehicle (BEV) lithium-ion battery (LIB) module are unavoidable: A cell-to-cell temperature difference of up to 5 K is generally considered acceptable within existing battery thermal management system (BTMS) concepts. However, the operating temperature of LIB cells plays a crucial role in their degradation … Read more
The cell to cell temperature gradient in a battery pack will limit the performance and lifetime. However, there will always be a cell temperature gradient and a cell to cell temperature gradient. It is very difficult not to have if we are rejecting or absorbing heat. The cell to cell temperature differences can be due … Read more
Whatever the cell format and however we cool it there will be a temperature gradient. This is described by Fourier’s Law of Conduction. An empirical law stating that the rate of heat flow is directly proportional to the temperature gradient and the area of heat transfer, and inversely proportional to the thickness of the material. … Read more
AION Engineering INC When selecting cells for a battery pack, one of the most critical considerations is the discharge C-rate. While datasheets provide discharge ratings, understanding the difference between continuous and peak discharge C-rates — and their thermal implications — is essential for safe and efficient battery design. What is Continuous Discharge C-Rate? The continuous … Read more