• Thermal Management Strategies for Lithium Battery Cells & Modules: Thermal management is crucial for maintaining the optimal temperature range of lithium battery cells and modules, which directly impacts their performance and safety. In this session, we will discuss various strategies for effective thermal management, including passive and active cooling methods, phase change materials, and thermal interface materials. We will explore the latest research findings, technologies, and best practices for optimizing thermal management in lithium battery cells and modules.

Bonding Techniques for Lithium Battery Cells & Modules: Proper bonding of battery cells and modules is essential for ensuring mechanical stability, electrical conductivity, and thermal conductivity, which are critical for reliable battery performance. In this session, we will focus on different bonding techniques, such as welding, gluing, and mechanical fastening, and their pros and cons for lithium battery cells and modules. We will also discuss the latest advancements in bonding materials, equipment, and process optimization for achieving robust bonding in lithium battery applications.

• Challenges and Solutions in Thermal Management and Bonding: The thermal management and bonding of lithium battery cells and modules present various challenges that need to be addressed to optimize their performance and safety. In this session, we will discuss common challenges, such as non-uniform temperature distribution, thermal runaway, and mechanical stress, and their impacts on battery performance and safety. We will also explore innovative solutions, such as advanced thermal management materials, design optimization, and bonding process improvements, to overcome these challenges and enhance the reliability and efficiency of lithium battery cells and modules.

• Case Studies and Best Practices: Real-world case studies and best practices related to thermal management and bonding of lithium battery cells and modules. Highlighting successful implementations, lessons learned, and key takeaways from experiences in optimizing thermal management and bonding techniques for lithium battery applications.

While significant resources are allocated to develop new battery technologies, vehicle manufacturers are looking into alternative fuel sources such as hydrogen due to stringent timelines to eliminate the sales of internal combustion engine (ICE) based vehicles. Fuel cell electric vehicles (FCEVs) operating with green hydrogen technology are a promising alternative to battery electric vehicles (BEVs). Fuel cells are more suitable for large vehicles such as trucks and trains considering the challenging battery size requirements for such large vehicles. In addition, they require less expensive commodities while tending towards zero emission, zero waste and no grid impact.

In this webinar, we will share a simulation driven methodology that can be adopted at any stage of propulsion system development for both BEVs and FCEVs with a robust, industry validated connected process. This includes leveraging pre-packaged workflows that apply to electric vehicles such as inverters and electric drives, as well as to bipolar plates and gas diffusion layers in hydrogen fuel cells. This highly scalable, customizable process will empower propulsion system engineering teams to develop solutions that are both suitable for the vehicle platform and exceed industry requirements.

• Our patented EV Protect 4006 increases EV battery safety by improving protection against fires and thermal propagation. Additional key benefits include corrosion protection, semi-structural support, NVH properties, impact resistance, while helping to maintain a stable internal battery temperature from extreme external environments

• HB. Fuller’s next generation innovative adhesive and sealant solutions provide improved thermal management performance, increase structural rigidity, and seal against external environments. We are dedicated to developing products that help provide a safer battery for the future

The session addresses a simple joining of materials with the highest conductivity joint – keeping electrical resistance (and heat generated) to a minimum – reducing heat, reducing cooling systems energy consumption- in tern contributing to increasing vehicle range.

E-Clinching is a unique and innovative joining technique that uses electrical current to form a mechanical bond between two or more electrical components. In this session, we will introduce the concept and principles of E-Clinching, including the equipment, process parameters, and materials involved. We will discuss the applications of E-Clinching in cell-to-cell connections in EV batteries, battery packs, modules, and cells, as well as other electrical components, such as electrical connectors and busbars. We will explore the advantages of E-Clinching, such as its one-step process, high speed, and repeatability, and its potential for reducing production time, cost, and complexity. We will also discuss the limitations and challenges of E-Clinching, such as material selection, process control, and joint quality, and share innovative solutions and best practices to overcome them.

Achieving Reliable Cell-to-Cell Joining with E-Clinching:

The reliability of cell-to-cell connections is crucial for the performance and safety of EV batteries and other electrical components. In this session, we will focus on the key factors that influence the reliability of cell-to-cell joints formed by E-Clinching. We will discuss the role of joint design, joint geometry, material properties, and process parameters in achieving reliable cell-to-cell joining. We will explore the importance of proper surface preparation, electrical current control, and process monitoring in ensuring consistent joint quality and performance. We will also discuss the impact of joint characteristics, such as resistance, mechanical strength, and thermal conductivity, on the overall electrical performance of the components. Additionally, we will share case studies, examples, and best practices of E-Clinching for achieving reliable cell-to-cell joining in various electrical components.

• Connecting aluminum, copper and other metals to connect leads and cells together

• How to connect different elements of the battery: E Clinching overview

• How the Tox e-clinching process works

• Solutions approach for the clinching process

• Solutions approach to oxide layer challenge

• Solutions approach for contact corrosion challenge

• Application samples

• E-clinching in multi-layer applications beyond two sheets

Overview of Battery Immersion Cooling:

In this session, we will provide an overview of battery immersion cooling, including the principles, benefits, and limitations of this technology. We will discuss how immersion cooling works, the types of cooling fluids used, and the different immersion cooling methods employed in EV battery packs and cells. We will also highlight the advantages and disadvantages of immersion cooling compared to other thermal management techniques, and discuss its potential for widespread adoption in the EV industry.

Current Challenges in Battery Immersion Cooling:

Despite the advantages of battery immersion cooling, there are several challenges that need to be addressed for its successful implementation in EV battery packs and cells. In this session, we will discuss key challenges, such as system design and integration, cooling fluid selection and management, corrosion and contamination risks, and safety considerations. We will explore the technical, economic, and regulatory challenges associated with battery immersion cooling, and discuss the latest research findings and industry practices in overcoming these challenges.

Materials and Technologies for Battery Immersion Cooling:

The selection of appropriate materials and technologies is critical for the effective implementation of battery immersion cooling. In this session, we will focus on the latest advancements in materials and technologies used in battery immersion cooling systems, such as cooling fluids, heat exchangers, pumps, sensors, and monitoring systems. We will discuss the performance, durability, and compatibility of these materials and technologies with battery packs and cells, and explore the ongoing research and development efforts to improve their efficiency, reliability, and safety.

Safety and Reliability of Battery Immersion Cooling Systems:

Safety and reliability are paramount considerations in the design and operation of battery immersion cooling systems. In this session, we will discuss the safety aspects of battery immersion cooling, including risks associated with cooling fluid leaks, electrical hazards, and fire hazards. We will explore the safety regulations and standards applicable to battery immersion cooling systems, and discuss best practices for ensuring the safe and reliable operation of these systems in EV battery packs and cells. We will also highlight the latest advancements in safety technologies, monitoring systems, and fail-safe mechanisms for battery immersion cooling.

Overview of Bonding, Sealing, and Potting in EV Battery Production: 

In this session, we will provide an overview of bonding, sealing, and potting as key technologies in EV battery production. We will discuss the importance of these processes in ensuring the structural integrity, electrical performance, and protection against environmental factors for battery packs. We will explore the different types of bonding, sealing, and potting techniques used in EV battery production, including adhesives, sealants, and potting compounds, as well as their applications and requirements in different battery pack designs and chemistries. We will also highlight the advantages and limitations of these technologies in EV battery production.

Current Challenges in Bonding, Sealing, and Potting for EV Battery Production:

Bonding, sealing, and potting processes in EV battery production come with their own set of challenges. In this session, we will discuss the key current challenges associated with these processes. This may include issues related to process reliability, repeatability, and scalability, as well as material compatibility, durability, and performance under varying operating conditions. We will also discuss the challenges related to process automation, cost optimization, and environmental regulations, as well as the need for standardization and quality control in bonding, sealing, and potting processes.

Material Selection and Process Optimization for Bonding, Sealing, and Potting in EV Battery Production:

The selection of appropriate materials and process optimization are critical for the successful implementation of bonding, sealing, and potting in EV battery production. In this session, we will focus on the latest advancements in materials and process optimization techniques for bonding, sealing, and potting. We will discuss the properties and characteristics of different materials used in these processes, such as adhesives, sealants, and potting compounds, and their suitability for different battery pack designs and operating conditions. We will also explore the process parameters, equipment, and techniques used for optimizing bonding, sealing, and potting processes in EV battery production, including surface preparation, curing, and quality control.

Reliability and Durability of Bonding, Sealing, and Potting in EV Battery Production:

Reliability and durability are critical factors in EV battery production, as the performance and safety of battery packs depend on the integrity of bonding, sealing, and potting processes. In this session, we will discuss the latest advancements in reliability and durability testing of bonded, sealed, and potted battery packs. We will explore the testing methods, standards, and protocols used for evaluating the performance and durability of bonded, sealed, and potted battery packs under various environmental conditions, such as temperature, humidity, vibration, and mechanical stress. We will also discuss the failure modes, mechanisms, and mitigation strategies related to bonding, sealing, and potting in EV battery production.

• Trade-offs with conventional modular design – Challenges with the old design include added weight and volume from the inactive portions of the module which ultimately translates into compromised pack energy density

• Next generation cell-to-pack configuration – Given these challenges, many EV and battery manufacturers are eliminating modules entirely and directly bond batteries to the cooling plate. This new module-free approach, referred to as “Cell-to-Pack” (CTP), reportedly increases volume-utilization space from 15-50%, depending upon battery cell design

• The benefits of thermally conductive gap fillers – Cell-to-Pack configurations offer numerous benefits, including increased volume-utilization space from 15-50%, reduction in the number of parts up to 40%, less expensive, lower energy density cells given the extra space, improvements to pack energy density, and more!

• Bonding automation offers numerous benefits, including improved process efficiency, reduced defects, the ability to explore new solutions, and significant cost savings. By streamlining tape and adhesive dispensing and application, automation enhances productivity, precision, and overall operational effectiveness.

• Partner with 3M to overcome your most critical bonding challenges, including tape and adhesive selection, design and simulation, and production automation.

• VHB™ Extrudable Tape is an innovative new solution that combines many of the benefits of a tape, with the automation capabilities traditionally limited to liquid adhesives.

• The RoboTape™ System for 3M™ Tape is an advanced solution that automates the application of 3M™ Tape in a process that was traditionally done manually.

• The 3M Bonding Process Center can help you see what is possible for automating your bonding application.  Collaborate with 3M’s team of tape and adhesive automation experts to design a process that fits your application needs.

• The 3M Bonding Automation Network is a collection of system integrators, dispensing companies and robotics experts that 3M will connect customers with to implement solutions.

Data-Driven Models for Battery SoH Prediction:

Data-driven models leverage historical battery performance data to predict the SoH of EV batteries. In this session, we will discuss the various data-driven models, such as regression models, neural networks, and decision trees, used for battery SoH prediction. We will explore the advantages and limitations of these models, including their accuracy, scalability, and adaptability to different battery chemistries, designs, and operating conditions. We will also discuss the challenges and best practices in data collection, feature selection, model training, and validation for effective SoH prediction.

Machine Learning Algorithms for Battery SoH Prediction:

Machine learning algorithms, which are a subset of data-driven models, have gained significant attention in battery SoH prediction due to their ability to handle large datasets and complex patterns. In this session, we will discuss the latest machine learning algorithms, such as support vector machines, random forests, and deep learning, used for battery SoH prediction. We will explore their capabilities, limitations, and applicability to different battery types and operating conditions. We will also discuss the challenges and opportunities in implementing machine learning algorithms for battery SoH prediction, including the need for high-quality data, model interpretability, and model deployment in real-time BMS.

Statistical Methods for Battery SoH Prediction:

Statistical methods have been widely used for battery SoH prediction due to their simplicity, interpretability, and reliability. In this session, we will discuss the various statistical methods, such as Kalman filters, Bayesian methods, and time-series analysis, used for battery SoH prediction. We will explore their strengths, weaknesses, and applicability to different battery chemistries, designs, and usage patterns. We will also discuss the challenges and best practices in statistical modeling for battery SoH prediction, including the assumptions and limitations of statistical methods, uncertainty estimation, and model updating for evolving battery conditions.

Applications of Battery SoH Prediction in BMS and Prognostics:

Battery SoH prediction has significant implications for BMS and prognostics in EVs. In this session, we will discuss the applications of battery SoH prediction in BMS, including state of charge (SoC) estimation, state of power (SoP) estimation, and thermal management strategies. We will explore how accurate SoH prediction can enhance the performance, safety, and reliability of BMS, as well as extend the lifespan of EV batteries. We will also discuss the applications of battery SoH prediction in prognostics, including remaining useful life (RUL) estimation, fault detection, and maintenance strategies. We will highlight the importance of incorporating battery SoH prediction in prognostics to enable proactive maintenance and optimize battery utilization.

Applications of Mechanical Fasteners in Battery Packs and Modules for Electric Vehicles:

The diverse applications of mechanical fasteners in battery packs and modules for EVs. Mechanical fasteners are used to secure battery cells, modules, and packs together, ensuring proper alignment, structural integrity, and electrical connections. We will explore the different types of mechanical fasteners used in EV battery systems, such as bolts, screws, nuts, clips, and brackets, and their specific applications in battery pack assembly, module attachment, and thermal management. We will also discuss the importance of selecting appropriate materials, designs, and torque specifications for mechanical fasteners to ensure optimal performance and reliability in EV battery systems.

Challenges in Using Mechanical Fasteners in Battery Packs and Modules for Electric Vehicles:

Using mechanical fasteners in EV battery systems comes with its own set of challenges. In this session, we will discuss the challenges associated with the use of mechanical fasteners in battery packs and modules for EVs. This may include issues related to thermal expansion and contraction, vibration, shock, corrosion, and fatigue, which can impact the integrity and performance of mechanical fasteners over time. We will also discuss challenges related to accessibility, assembly complexity, and cost-effectiveness in using mechanical fasteners in EV battery systems. Additionally, we will explore challenges in meeting safety and regulatory requirements, such as crashworthiness, electrical isolation, and thermal management, when using mechanical fasteners in EV battery systems.

Solutions and Best Practices for Using Mechanical Fasteners in Battery Packs and Modules for Electric Vehicles:

In this session, we will discuss the solutions and best practices for using mechanical fasteners in battery packs and modules for EVs. This may include advancements in fastener materials, designs, coatings, and treatments that enhance their performance in EV battery systems. We will explore techniques for optimizing torque specifications, fastener installation, and inspection to ensure proper fastening and prevent issues such as over-tightening or under-tightening. We will also discuss best practices in selecting appropriate fasteners for specific applications in EV battery systems, considering factors such as load-bearing capacity, vibration resistance, corrosion resistance, and assembly complexity. Additionally, we will discuss strategies for addressing challenges related to accessibility, assembly complexity, and cost-effectiveness, while maintaining safety and regulatory compliance in using mechanical fasteners in EV battery systems.

Future Directions in Mechanical Fasteners for Electric Vehicle Battery Systems:

The field of mechanical fasteners for EV battery systems is constantly evolving, and new technologies and trends are shaping the future of fastening solutions. We will discuss the future directions in mechanical fasteners for EV battery systems. We will explore emerging technologies, such as smart fasteners, self-healing fasteners, and lightweight fasteners, that could offer improved performance, efficiency, and sustainability in EV battery systems.

Sustainable Coating Solutions for Battery Systems:

Coating technologies are essential for the protection, insulation, and performance enhancement of battery systems. We will discuss sustainable coating solutions for battery systems and explore innovative coating technologies, such as thermal management coatings, corrosion protection coatings, and barrier coatings, that provide long-term protection and enhance the performance of battery systems. We will look at the environmental impact, durability, and performance benefits of coating solutions, and how they contribute to the sustainability of battery systems as well as the application methods, process optimizations, and performance testing of coating technologies in battery system manufacturing, and their role in enabling high-performance and sustainable battery systems.

System Integration Solutions for Battery Systems:

The integration of battery systems into EVs requires advanced solutions for electrical, thermal, and mechanical interfaces. This session will discuss system integration solutions for battery systems and explore innovative technologies, such as gasketing, potting, and encapsulation, that provide reliable and efficient sealing, insulation, and protection of battery systems; integration solutions, such as flexibility, thermal stability, and mechanical strength, that are essential for the demanding requirements of battery systems.

Sustainability and Circular Economy in Battery Systems:

Sustainability and circular economy principles are becoming increasingly important in the design, manufacturing, and management of battery systems. Discussing the approach to sustainability and circular economy in battery systems we will explore efforts in developing sustainable products, optimizing manufacturing processes, and promoting responsible battery management practices. We will explore the environmental impact, resource consumption, and circularity of technologies and solutions for battery systems and examine case studies and examples of successful sustainability and circular economy initiatives in battery systems; the lessons learned and best practices for incorporating sustainability and circular economy principles into battery system design, manufacturing, and management.

In this webinar, we present the value of using a unified modeling and simulation process that leverages the CAD-CAE connectivity for developing a new electric drive system or re-using one from an existing vehicle program. With the creation of a modular, fully-parametric and simulation-friendly electric drive model, it is possible to explore untouched design possibilities and test all possible scenarios in a more affordable time frame—thereby, accelerating the vehicle development program and preventing valuable engineering resources from being wasted.

• Key challenges in electric drive development

• Automated, highly-flexible solution package for electric drive development

• Design driven by multi-physics performance attributes based on fully-parametric model

• MODSIM realization enabling efficient collaboration beyond domain boundaries

• Leveraging best possible design solution with multi-fidelity modeling

To meet the evolving requirements, innovative battery test solutions are essential for evaluating battery performance, characterizing battery behavior under different operating conditions, and ensuring battery safety and reliability. In this session, we will delve into the key challenges associated with battery testing for EVs and explore innovative solutions to address these challenges.

Evolving Battery Requirements for Electric Vehicles:

In this session, we will discuss the evolving battery requirements for electric vehicles. As the electric vehicle market continues to grow, battery technologies are rapidly advancing, and the performance, safety, and reliability requirements for EV batteries are becoming more stringent. We will explore the latest advancements in battery chemistries, cell designs, and pack configurations, as well as the increasing demand for extended range, fast charging, and improved durability in EV batteries. We will also discuss the evolving regulations, standards, and testing protocols for EV batteries, and how these requirements pose challenges for battery testing.

Key Challenges in Battery Testing for Electric Vehicles:

Battery testing for EVs comes with its own set of challenges. In this session, we will discuss the key challenges associated with battery testing for electric vehicles. This may include issues related to test accuracy, repeatability, and reproducibility, as well as the need for comprehensive testing of various battery parameters, such as capacity, power, efficiency, thermal behavior, and safety performance. We will also explore challenges related to test automation, scalability, and adaptability to evolving battery technologies and requirements. We will discuss the limitations of traditional battery testing methods and equipment, and how these challenges impact the development, validation, and production of EV batteries.

Innovative Battery Test Solutions for Electric Vehicle Batteries:

Innovative battery test solutions are essential to address the evolving requirements of EV batteries. In this session, we will explore the latest advancements in battery test solutions for electric vehicles. We will discuss innovative approaches to battery testing, such as advanced battery characterization techniques, accelerated aging tests, real-time monitoring, and simulation-based testing. We will also discuss advancements in battery testing equipment, software, and data analysis tools that enable more accurate, reliable, and efficient testing of EV batteries. We will highlight case studies, examples, and success stories of innovative battery test solutions implemented by leading companies and research institutions.

Future Directions in Battery Testing for Electric Vehicles:

The field of battery testing for EVs is constantly evolving, and new trends and directions are shaping the future of battery testing. In this session, we will discuss the future directions in battery testing for electric vehicles. We will explore emerging technologies, methodologies, and standards for battery testing, such as in-situ testing, non-destructive testing, and virtual testing. We will also discuss the potential impact of artificial intelligence, machine learning, and big data analytics in battery testing, and how these technologies can enable more efficient, accurate, and predictive battery testing. We will discuss the challenges and opportunities in implementing these future directions and their potential impact on the development, validation, and production of EV batteries.

Plasma Cleaning for Surface Preparation and Activation in EV Battery Sealing Systems:

Plasma cleaning has emerged as a powerful technique for surface preparation and activation in EV battery sealing systems. In this session, we will discuss the applications of plasma cleaning in battery pack, module, and cell sealing systems. Plasma cleaning is used for removing contaminants, such as oils, greases, and oxide layers, from battery component surfaces to improve the adhesion of coatings, adhesives, and sealants. We will explore the advantages of plasma cleaning in terms of cleanliness, uniformity, and speed. We will also discuss challenges, such as plasma parameter optimization, material compatibility, and safety, in plasma cleaning for EV battery sealing systems, and share innovative solutions and best practices to overcome them.

Selective Coating for Precise and Controlled Deposition in EV Battery Sealing Systems:

Selective coating has emerged as a promising technique for precise and controlled deposition of coatings in EV battery sealing systems. In this session, we will discuss the applications of selective coating in battery pack, module, and cell sealing systems. Selective coating allows the deposition of coatings on specific areas of the battery components, such as gaskets, joints, and interfaces, to enhance the sealing performance. We will explore the advantages of selective coating in terms of accuracy, repeatability, and customization options. We will also discuss challenges, such as coating material selection, process control, and cost-effectiveness, in selective coating for EV battery sealing systems, and share innovative solutions and best practices to address them.

Long-term Sealing System Performance for EV Batteries:

The sealing system performance is crucial for the long-term reliability and safety of EV batteries. In this session, we will discuss the factors that affect the sealing system performance, including environmental factors, temperature changes, mechanical stresses, and chemical exposure. We will explore the importance of proper surface preparation, coating deposition, and curing in achieving a durable and effective sealing system. We will also discuss the role of plasma cleaning and selective coating in improving the sealing system performance and mitigating common issues, such as leaks, degradation, and failure. Additionally, we will share case studies, examples, and best practices of plasma cleaning and selective coating for achieving long-term sealing system performance in EV batteries.

Innovations and Future Directions in Plasma Cleaning and Selective Coating for EV Battery Sealing Systems:

Plasma cleaning and selective coating are rapidly evolving technologies with continuous innovations and advancements. In this session, we will discuss the latest developments, trends, and future directions in plasma cleaning and selective coating for EV battery sealing systems

• Simulation is used extensively in the EV market to test structures virtually, reducing the time and resources required for physical testing. Material models for standard engineering materials are readily available, but adhesives exhibit more complex types of mechanical behaviors and thus require advanced testing and material calibration methods.

• 3M supports customer simulation needs by providing adhesive material data cards that can be imported directly into FEA software.

• The most suitable material model for simulating an adhesive depends on how the adhesive responds to loads and the objectives of the simulation. Viscoelastic models are typically employed to simulate pressure-sensitive adhesives or tapes, whereas linear elastic-plastic models or cohesive zone models are commonly used for simulating structural adhesives.

Importance of Cell Temperature in EV Battery Performance and Design:

Discussing the importance of monitoring cell temperature in optimizing EV battery performance and design. Exploring the effects of temperature on battery capacity, charging efficiency, power output, and cycle life. We will discuss the challenges posed by temperature variations during battery operation, such as thermal runaway, degradation, and safety risks and the implications of cell temperature on battery pack design, thermal management strategies, and overall system performance. We will highlight the need for accurate and real-time cell temperature monitoring to optimize EV battery performance and design.

Technologies and Techniques for Cell Temperature Monitoring:

Monitoring cell temperature requires advanced technologies and techniques that provide accurate and real-time temperature data. In this session, we will discuss the state-of-the-art technologies and techniques for cell temperature monitoring in EV batteries. We will explore various temperature sensors, such as thermocouples, resistance temperature detectors (RTDs), thermistors, and infrared thermography, and their suitability for EV battery applications. We will discuss the advantages and limitations of different temperature monitoring techniques, such as contact and non-contact methods, distributed and localized sensing, and online and offline monitoring. We will also discuss the integration of temperature monitoring systems into EV battery packs and modules, and the challenges and best practices in sensor placement, calibration, and data acquisition.

Data Analysis and Modeling for Cell Temperature Optimization:

Monitoring cell temperature is just the first step; the real value comes from analyzing the temperature data and optimizing battery performance accordingly. In this session, we will discuss the data analysis and modeling techniques for optimizing cell temperature in EV batteries. We will explore the use of data analytics, machine learning, and modeling approaches to analyze temperature data, identify patterns, and derive insights for battery performance optimization as well as the development of temperature models, such as electro-thermal models, thermal-electrical models, and multi-physics models, for predicting cell temperature under different operating conditions. We will also discuss the integration of temperature optimization algorithms into battery management systems (BMS) and the challenges and opportunities in leveraging data analysis and modeling for cell temperature optimization in EV batteries.

Case Studies and Best Practices for Cell Temperature Optimization:

Real-world examples and best practices are invaluable in understanding the practical aspects of cell temperature optimization in EV batteries. This session aims to share case studies and best practices from industry experts and researchers on cell temperature optimization showcasing successful examples of how cell temperature monitoring and optimization have been implemented in EV battery systems to improve battery performance, extend battery life, and enhance safety. We will highlight the challenges encountered in implementing cell temperature optimization strategies, such as thermal management, cooling, and heating, and the best practices adopted to overcome these challenges. We will also discuss the lessons learned, future trends, and recommendations for optimizing cell temperature in EV batteries.

Plastic components can be used in various ways in EV battery modules and packs, ranging from structural supports, enclosures, thermal management elements, and electrical insulation components. In this session, we will discuss the applications and benefits of plastic components in EV battery systems. We will explore how plastic materials, such as high-performance polymers and composites, can offer lightweight solutions, reduce manufacturing costs, and improve design flexibility in battery modules and packs. We will also discuss the advantages of plastic components in terms of corrosion resistance, electrical insulation, thermal management, and environmental sustainability.

Challenges and Innovations in Utilizing Plastic Components in Battery Systems:

While plastic components offer many opportunities for enhancing EV battery systems, they also pose challenges that need to be addressed. In this session, we will discuss the key challenges and innovations in utilizing plastic components in battery modules and packs. We will explore the issues related to material selection, mechanical properties, thermal performance, and safety considerations of plastic components in battery systems. We will also discuss the impact of environmental factors, such as temperature, humidity, and ageing, on the performance of plastic materials in battery applications. We will share innovative solutions, technologies, and best practices for overcoming these challenges, such as advanced material formulations, surface treatments, and manufacturing techniques. We will also discuss the importance of testing, validation, and certification of plastic components in battery systems to ensure their reliability and safety.

Future Directions and Emerging Trends in Plastic Components for EV Batteries:

Plastic materials and technologies are constantly evolving, opening up new opportunities and possibilities for enhancing EV battery systems. This session, will discuss the future directions and emerging trends in plastic components for EV batteries. We will explore the latest developments in plastic materials, including high-performance polymers, composites, and additives, that offer improved properties, such as higher thermal conductivity, better flame resistance, and enhanced mechanical strength. We will also discuss the use of additive manufacturing, also known as 3D printing, for producing plastic components with complex geometries and optimized performance. We will explore the potential of plastic components in enabling emerging battery technologies, such as solid-state batteries and flexible batteries. We will also discuss the role of plastic components in achieving circular economy and sustainable practices in the design, manufacturing, and end-of-life stages of EV battery systems.

In this session, we will discuss the latest advancements in HV and LV batteries for next-generation EVs. HV batteries, typically used for powering the main propulsion system, are designed to provide high power and energy density, enabling long-range driving. On the other hand, LV batteries, used for auxiliary systems such as lighting, infotainment, and power electronics, are designed to provide lower power and energy requirements. We will explore the advancements in battery chemistries, materials, designs, and manufacturing techniques that enable higher energy density, faster charging, longer lifespan, and improved safety for both HV and LV batteries. We will also discuss the trends in battery management systems, thermal management, and safety features that optimize the performance and reliability of HV and LV batteries in next-generation EVs.

Challenges and Synergies in Integrating High Voltage and Low Voltage Batteries in Electric Vehicles:

Integrating HV and LV batteries in EVs comes with its own set of challenges and opportunities. In this session, we will discuss the challenges associated with the integration of HV and LV batteries in next-generation EVs. This may include issues related to system architecture, power electronics, electrical interfaces, and safety requirements. We will explore the synergies and trade-offs between HV and LV batteries, such as balancing power distribution, optimizing charging and discharging strategies, and managing energy flow between the two battery systems. We will also discuss the impact of the power partnership between HV and LV batteries on overall vehicle performance, efficiency, and cost-effectiveness.

Applications and Benefits of High Voltage and Low Voltage Batteries in Next-Generation Electric Vehicles:

HV and LV batteries in next-generation EVs have diverse applications and benefits. In this session, we will discuss the various applications of HV and LV batteries in next-generation EVs, beyond their traditional roles. This may include using HV batteries for fast charging, regenerative braking, and peak power demands, and using LV batteries for vehicle-to-grid (V2G) applications, powering auxiliary systems, and providing backup power. We will explore the benefits of leveraging the power partnership between HV and LV batteries in optimizing the overall vehicle performance, extending battery life, enhancing driving range, improving charging efficiency, and enabling new features and functionalities in next-generation EVs.

Future Directions in High Voltage and Low Voltage Batteries for Electric Vehicles:

The field of HV and LV batteries for EVs is rapidly evolving, and new trends and directions are shaping the future of EV powertrains. In this session, we will discuss the future directions in HV and LV batteries for next-generation EVs. We will explore emerging technologies, such as solid-state batteries, advanced power electronics, and energy management systems, that could revolutionize the power partnership between

The industry has seen incredible advances in high voltage cell manufacturing over the past several years with the rise and increase of electrified powertrains but what about the low voltage battery? Is there a future? Learn more about the ever increasing role of the 12V battery in electrified powertrains and how much vehicles in the future will depend on it

• AFM – Applications of AFM that relate to nanoimaging of battery components and interfaces.

• SEM – Cleanliness, particle size, shape, and composition analysis of powders and electrodes using EDS, EBSD, and WDS.

• NMR –Leveraging diffusion and conductivity data from NMR for formulation development to gain insight into energy density along with charge/discharge performance.

• Raman Imaging – Investigating the cycling-induced chemical changes and degradation of cathodes, anodes and separators.