Electric Vehicle Manufacturing Event Calendar 2022

THURS 14 JULY  3PM (CET) 9AM (ET)

Advances In Thermally Conductive, Electrically Insulated Materials For E-Mobility Applications

Ray L. Szparagowski, Technical Director, Automotive and High Performance Plastics, Global Fluid Power Division, Freudenberg Sealing Technologies

Speaker Bios | Company Profile

Plastics are often used in electric components. For these materials, many requirements such as mechanical properties, temperature capability, flammability, thermal conductivity, and mold ability, among others, are considered in their selection. In addition, electrical resistance is required to isolate the system for safety reasons. In general, plastics are good electric isolators (electrically safe) but poor conductors of heat compared to metals.

In response to this challenge, work in developing Thermally Conductive Electrically Insulated (TCEI) materials has become an important focus for use in E-Mobility applications. Fillers play an important role in material properties of plastics, and Freudenberg Sealing Technologies, with its expertise in filled polymeric systems, has developed multiple new grades of TCEI materials that demonstrate improved conductivity over commercially available choices. The company has quantified the thermal conductivity of these novel materials using a unique finite element model to capture the effect of material choice on temperatures within systems. The model incorporates material orientation and also evaluates effect of air gap between components. Results show that materials with improved thermal conductivity can significantly reduce temperatures in applications.

• Plastic grade materials that improve thermal management for temperature control and maintain electrical resistance for safety.

• TCEI (Thermal Conductive Electrically Isolating) grades offer significant improvements in temperature control in E-Mobility applications.

• FST advanced modeling techniques can evaluate application design and material  impacts on temperatures to address critical hot spots that can occur.

• E-motor applications such as bobbins and slot liners have shown significant temperature reduction using these new TCEI materials.

FRI 15 JULY 3PM (CET) 9AM (ET)

Senior Flexonics Brazing Capabilities With Case Study Review Of Battery Cooler Brazing Development

Grant Kiel, Senior Advanced Development Engineer, Senior Flexonics

Speaker Bios | Company Profile

• Overall Brazing Capabilities

• Types of Brazing

• Brazing Materials

• Case Study on Brazing Stainless Battery Cooler

• Overview of Design

• Brazing Challenges

• Braze Alloy and Application Method

• Braze Fixture Development

TUES 19 JULY 3PM (CET) 9AM (ET)

Thermal Propagation Prevention: Materials, Application, & Automation Techniques

Stephen Neuman, Director of eMobility and EV Battery, Graco Inc

Speaker Bios | Company Profile

• The basics of how thermal events (runaway and propagation) occur.

• Why this is a critical factor in the proliferation of eMobility

• Mitigation Strategies – Interstitial Encapsulation, Intumescent Coatings, Thermal Interface Materials

• Material chemistries

• Design considerations for implementing best practices and process through the lens of mass manufacturing

• The importance of considering manufacturability early in the module design phase

The Basics Of UN 38.3 And The Requirements For The Transportation Of Lithium Batteries

Rich Byczek, Global Technical Lead For Electric Vehicle & Energy Storage, Intertek

Speaker Bio | Company Profile

• Cell and Battery Types & Definitions

• Latest updates to the UN 38.3, 7th Edition requirements

• Which tests are required for each type

• When and how to reduce samples and testing

• Interpreting the test criteria and when does a new battery require testing

• And more…

Cell & Battery Abuse: Development Of Thermal Runaway / Propagation Tests For EV & Stationary Batteries

Rich Byczek, Global Technical Lead For Electric Vehicle & Energy Storage, Intertek

Speaker Bio | Company Profile

• Understand the key regulatory and standards roadmaps for EV, Stationary and eMobility battery applications

• Thermal runaway and propagation occurrences in the real world

• Key Thermal runaway test requirements and standards

• Methods of inducing single cell events in the lab environment

• Scaling to module and system tests

• Test criteria, data collection and measurement methods

• Limitations and challenges in test environments

• And more…..

EVSE Charging And Safety Standards, Going Beyond Level 1 And 2

Rich Byczek, Global Technical Lead For Electric Vehicle & Energy Storage, Intertek

Speaker Bio | Company Profile

• AC and DC charging safety standards

• Cord sets through DC Fast Charge

• Wireless charging considerations

• North America and International markets

• Micro mobility applications

• Commercial Vehicle charging

• Non-typical installations

• And more…

Improve Process Efficiency Through Thermal Adhesive Simulation For Tool Path Optimization & Module Assembly

Jennifer Weiche, Simulation Analysis Engineer, AVL

Juergen Schneider, Senior Solution Manager Virtual Battery Development, AVL

Speaker Bios | Company Profile

For optimal cooling of battery packs and power electronics, it is of crucial importance that thermal grease (paste) is applied reliably in the battery manufacturing process. This ensures proper battery safety during operation and avoids warranty work.

• Learn how simulation supports the development of automated manufacturing processes and improves production efficiency

• Minimize squeeze-out losses during module assembly

• Achieve wet-out targets through process optimization

• Innovative solutions for simulating highly viscous materials

Battery Immersion Cooling: The Lightest And Safest Solution For EVs And HEVs

Rémi Daccord, CTO and Founder, E-MERSIV and EXOES

Mathieu Guery, Project Manager, E-MERSIV

Speaker Bio | Company Profile

• What does the market expect from EVs?

• Different types of battery thermal management systems

• How does this new cooling technology work?

• What are the advantages of immersion cooling?

• E-MERSIV: Manufacturer of immersion cooled batteries.

• Products developed by E-MERSIV

• Tests carried out on E-MERSIV products
  

• What is E-MERSIV’s target market?

Engineering The Thermal & Safety Challenges In Next-Generation Battery Packs

Bret A. Trimmer, Applications Engineering Manager – NeoGraf Solutions

Speaker Bios | Company Profile

• The best current methods for EV battery thermal management will be reviewed.

• The four primary strategies that battery pack manufacturers use to prevent Thermal Runaway will be discussed.

• Each propagation control method introduces benefits or harm to the cells in terms of fast charging, cell cycle lifetime, charge rate, and driving range.

• For applications where smaller-pack-size and lighter-weight are important, flexible graphite will be discussed as a direct substitute for aluminum.

Thermal Conductive Adhesives For Next Generation Cell-to-Pack Configurations

Dr. Tim Fornes, Technology Fellow, Advanced Technology, Parker LORD

Susan Donaldson, Scientist I in the Advanced Technology Department, Parker LORD

Speaker Bios | Company Profile

A new class of thermally conductive adhesives have been developed for directly bonding prismatic battery cells to cooling plates. This lightweight technology not only affords higher energy density in EVs, but greatly reduces manufacturing cost and complexity.

Key Takeaways:

• One route to achieving these goals is the elimination of the housings of battery modules and bonding individual cells directly to the cooling plate. This simplification eliminates numerous steps, parts, and materials. We’ll discuss the shift towards this design and how it benefits manufacturers when using thermal management materials

• New adhesive technology is needed to meet more demanding performance requirements. This talk will review new developments in thermally conductive adhesives that enable direct bonding of prismatic cells to aluminum cooling plates.

• Comparisons between the new cell-to-pack design and traditional battery pack configurations will be discussed.

Use Of Adiabatic Calorimetry In Battery Safety

Danny Montgomery, Technical Performance Manager, Thermal Hazard Technology

Speaker Bio | Company Profile

The webinar will describe the use of adiabatic calorimetry techniques that can be used to carry out safety testing of batteries. The theoretical background of the ARC (Accelerating Rate Calorimeter) test method will be described and recommended practice for various types of testing will be discussed. Batteries are be studied under either normal or abuse conditions. This information can be used to aid design of battery management/safety systems. As well as thermal data, pressure measurement and gas analysis are also available.

This webinar will focus on the following key topics:

• Principle of adiabatic calorimetry

• Advantages and limitations of the method

• Determining the stability and safety of batteries

• Electrical abuse in the form of short circuit, over-charge or over-discharge.

• Mechanical abuse by nail penetration or crushing.

• Thermal abuse via Heat-Wait-Seek (HWS), ramp heating or hotbox.

• Determining battery efficiency and thermal management

Building Digital Twins Towards A Complete, Faster, Cost Effective & More Optimal Design Of Vehicles

Chin-Wei Chang, SIMULIA IPS | T&M Industry Process Expert Specialist, Dassault Systèmes

Dave Mukutmoni, SIMULIA IPS | T&M Industry Process Expert Specialist, Dassault Systèmes

Speaker Bios | Company Profile

In this presentation, we describe the simulation tools and workflows used for thermal design of vehicles; establish that these tools are accurate, and detail their implementation at both the component and vehicle integration level. We also show that use of these digital twin technologies leads to significant savings in both time and cost and is therefore a must have capability.

• Introduce workflows and tools used to build digital twins for thermal analysis and how this leads to savings in time and resources

• Describe how complete and accurate these tools and their impact on design both at the component and vehicle integration level

• Highlight use cases that show the tools are streamlined and automated that enables non-specialists to implement them

ON DEMAND

In Pursuit Of Silence Inside BEVs: The New Products Behind The Next Level Of Acoustic Comfort

Davide Caprioli, Head of Product Acoustic and Thermal Performance, Autoneum

Philippe Godano, Global Product Manager Interior Floor, Autoneum

Speaker Bios | Company Profile

• The new sources of noise inside a BEV do not carry an emotional message like an engine sound does

• What is the expectancy of the public in terms of acoustic comfort?

• The new sources of noise of a BEV: what should the sound package look like considering dedicated platforms’ designs?

• Treatment of e-powertrain high frequency tonal noises by encapsulation

• Efficient sound package to reduce rolling noise

ON DEMAND

Don’t Just Delay Cell-to-Cell Thermal Propagation, Stop It

John Williams, VP of Technical Services, Aspen Aerogels

Speaker Bios | Company Profile

• Learn about the role of compression pads and cell-to-cell barriers in managing mechanical and thermal energy inside a module and/or pack

• Review the landscape of possible solutions, including foams, fibers, foils, and aerogels

• Understand how energy and material flows during a thermal event

• See thermal propagation stopped cold in real-world testing of PyroThin, an aerogel-based thermal barrier

ON DEMAND

Liquid Cooling For EV Charging: How To Make Connections That Drive Performance & Reliability

Christopher Winslow, Applications Engineer, Thermal Business Unit, CPC

Rakesh Yedla, Applications Development Manager, Thermal Business Unit, CPC

Speaker Bios | Company Profile

• What system types benefit from quick disconnects and where they are located within battery and EV Charging systems

• Which are the most important quick release coupling specifications for ensuring adequate cooling

• Why purpose-built for liquid cooling connectors are superior for keeping umbilical’s, station/pile electronics and batteries cool

• What termination options are typically available and which are ideally suited for EV charging cooling

• How coolant selection impacts connector reliability

• Questions to ask suppliers regarding flow, testing, spillage and manufacturing processes

ON DEMAND

Thermal Management & Bonding of Lithium Battery Cells & Modules

Ralf Hoffmann, PhD, Head of New Business Development, ELANTAS GmbH

James Herbison, Head of Basic Research, ELANTAS PDG

Speaker Bios | Company Profile

Learn about the optimal materials needed for the bonding of battery packs for today’s EV lithium batteries, as well as thermal management of the packs or modules.

• Bonding the battery packs to the module of frame (to the heat sink, individual packs, or the modules to each other)

• Gap sealing between the packs

• Thermal management materials taking heat from the modules or packs through to the heat sink

• Sealing of the module or box that the batteries are packed into