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
The exact number of temperature sensors you need depends on the size of your battery pack, its physical configuration, rate of charge/discharge (C-rate), and the required level of thermal observability. In commercial Battery Management Systems (BMS), it is common practice to use one temperature sensor for every 4 to 20 cells, depending on the specific … 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
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
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
Prismatic cells are typically surface-cooled when used in real world scenarios, and we have observed a growing demand for testing methods that align to this. Thus we have been investigating the best methods for replicating the conditions a battery may be used in. Recently, we conducted a surface cooling test on a 314Ah prismatic cell. … Read more
AION Engineering INC Cylindrical cells are widely recognized as the most suitable format for high-speed roll-to-roll production, offering scalability and manufacturing efficiency. However, despite their structural advantages, thermal management remains a critical design challenge, especially under high-power operating conditions. Cylindrical cells are widely recognized as the most suitable format for high-speed roll-to-roll production, offering scalability … Read more
Specific heat capacity (Cp) is a fundamental physical property that describes the amount of heat required to change the temperature of a substance by a given amount, typically per unit mass. Expressed in units like joules per kilogram per degree Celsius (J/kg°C) or calories per gram per degree Celsius (cal/g°C), it quantifies the thermal inertia … Read more
Fast introducing battery electric vehicles to the market leads to the accumulation of errors and recalls of the vehicle. It can be avoided by simulating battery electric vehicles (BEV) in an integrated manner. Electric vehicle thermal management is key in optimal performance of a vehicle. A drivetrain model is developed integrated with cabin, battery, and … Read more