EV traction battery with thermal storage

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The EU OPTEMUS (Optimized Vitality Administration and Use) mission seeks to deal with the electrical vary limitation attributable to restricted storage capability of electrical batteries by leveraging low power consumption and power harvesting by a holistic vehicle-occupant-centered method, contemplating house, value and complexity necessities.

Particularly, OPTEMUS intends to develop quite a lot of progressive core applied sciences (Built-in thermal administration system comprising the compact refrigeration unit and the compact HVAC unit, battery housing and insulation as thermal and electrical power storage, thermal power administration management unit, regenerative shock absorbers) and complementary applied sciences (localized conditioning, comprising the sensible seat with carried out TED and the sensible cowl panels, PV panels) mixed with clever controls (eco-driving and eco-routing methods, predictive cabin preconditioning technique with min. power consumption, electrical administration technique).

Among the many OPTEMUS tasks is a traction battery with thermal storage, which the Fraunhofer Institute for Structural Sturdiness and System Reliability LBF has helped to design.

The part change materials composite system developed by the Fraunhofer LBF can be utilized to precondition the temperature-sensitive battery cells in chilly climate and to maintain them at this optimum working temperature for longer utilizing the thermally insulating housing. An energetic temperature management can thus often be averted.


A novel part change materials composite is thermally decoupled from the atmosphere by an insulating sandwich housing.

Conversely, it’s doable to mitigate short-term, undesirable warmth will increase of the battery, which can happen throughout speedy charging.

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With a purpose to thermally decouple the PCM composite from the atmosphere and thus make it simpler to regulate, scientists from the Fraunhofer LBF have developed a way for producing a thermally insulating, high-strength battery housing.

That is primarily based on a foam injection-molded integral polymer foam (SABIC PP15T1020), which is domestically strengthened with high-strength thermoplastic fiber-plastic composites (TP-FKV) utilizing the hybrid manufacturing course of. Right here, the froth ensures the insulating potential.

So as to have the ability to examine and consider completely different polymer foams with regard to their foam morphologies and thus the isolation functionality, the researchers designed a morphology evaluation primarily based on pc tomographic 3D photographs.

For the reason that polymer foam has solely low strengths and stiffnesses, it’s coated with TP-FKV with the intention to safely carry the working masses on the battery. For this objective, the LBF scientists made a laminate out of a number of zero.25 mm skinny unidirectional tapes (UDMAX from SABIC) and deformed it in three dimensions earlier than the integral foam was injected as a core between the laminate cowl layers within the hybrid manufacturing course of.

The ensuing sandwich development has a number of benefits: It has a excessive light-weight potential and results in excessive particular bending properties and impression resistance. As well as, it gives a excessive degree of safety in opposition to intrusion occasions, which play a significant security position particularly in battery packs.

With a purpose to do justice to the automotive utility, each materials and structural ideas have been developed in order that they will also be utilized in large-scale manufacturing. For instance, the manufacturing of the thermally insulating housing is realized by a hybrid foam injection molding course of developed on the Fraunhofer LBF, which for the primary time makes it doable to provide cost-efficient three-dimensional FRP sandwich parts briefly cycle occasions at comparatively low materials prices.

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