Summary
- Fraunhofer Institute for Machine Tools and Forming Technology IWU and partners are developing next-generation battery enclosures for EVs
- COOLBat project aims to make lighter enclosures by combining individual systems, packing more functions into a smaller space, and using new materials
- Aluminum foam inside the base plate absorbs impact energy and reduces the amount of energy needed to cool the battery
- Researchers are replacing heavy conductive pastes with ecofriendly heat-conductive materials to connect the battery module
- Future plans include extending project results to other industries that use large batteries, such as trains, aircraft, and boats
Article
Researchers at the Fraunhofer Institute for Machine Tools and Forming Technology IWU in Germany collaborated on the COOLBat joint research project to develop innovative battery enclosures for electric vehicles. The project focuses on creating lighter enclosures to improve power consumption and driving range by incorporating multiple systems into a smaller space and utilizing new heat-conductive materials and bio-based flame-retardant coatings.
Through the COOLBat project, researchers have explored the integration of various systems within the enclosure that previously served thermal and mechanical functions separately. By combining the cooling unit function with underride protection into a single component, known as the base plate, the researchers are able to optimize the design for improved performance and efficiency.
Inside the base plate, aluminum foam is used to absorb impact energy from stone impacts and accidents, while a phase-change material (PCM) can store and release thermal and cooling energy. This setup helps protect battery cells from mechanical loads and overheating. Additionally, a fluid flows through channels to cool the cells from below and the sides, reducing the energy required for cooling and eliminating the need for cooling elements in other parts of the vehicle.
As part of the project’s goals, researchers aim to replace heavy conductive pastes with more environmentally friendly heat-conductive materials to connect the battery module for thermal purposes. By using a plasma process to metallize reusable foams placed between the battery and enclosure, the team is working to enhance the overall performance and sustainability of the battery system.
To improve safety measures, a new flame-retardant coating has been developed for the underside of the enclosure lid to prevent fires from spreading. The previous steel lid has been replaced with a lightweight fiber composite lid, reducing the component’s mass and enabling reuse. The research team is using the Mercedes-Benz EQS battery as a reference and technological demonstrator for their work.
Looking ahead, the project’s outcomes are expected to have applications beyond electric vehicles, benefiting other industries that utilize large batteries, such as trains, aircraft, and boats. By focusing on functionally integrated structures, the researchers aim to consolidate tasks previously handled by separate modules in the battery system into a single component, like the base assembly. This approach will help optimize space utilization, enhance safety measures, and protect the battery core in various scenarios.
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