6 Key insights from Tecman's Thermal Management conference session

1. The difficulty & complexity of the challenge is increasing

The rapid evolution of the EV industry presents significant hurdles and a steep learning curve for automotive engineers. Developing next-generation systems to meet escalating demands and stringent regulations is a complex challenge.

Optimising battery cell performance, by balancing cell expansion, compression, and lifecycle requirements adds further complexity.

On top of these basic requirements, the constant drive for more energy per pack to deliver ‘better range’, which means more high powered cells in a smaller and smaller package space, intensifies the challenge. 

2. High performance solutions do exist

The complexity of the challenge can be overwhelming, however Tecman strongly believes that by getting the right minds around the table these challenges can be solved. 

Working very closely with engineers, technical experts, scientists and supply partners we have collaborated with major OEMs to solve these challenges. Key to the process is focusing on the right materials, part design, manufacturing process, and cost to deliver high-performance solutions.

3. Solutions need to be scalable

Today’s EV thermal management challenges require innovation that is scalable and cost effective. Whilst many promising new 'lab' solutions and experimental materials appear in the headlines, transitioning to high volume production can be time consuming and expensive. 

Tecman’s ATP Pads are fully developed and commercially proven thermal runaway barriers that meet all technical and functional requirements. Additionally, our high-speed, automated manufacturing system makes us highly competitive with low-cost regions. 

4. High trust collaboration is key for success

Successful battery development projects between OEMs and suppliers hinge on high trust collaborative environments with transparency and fair treatment of all stakeholders. These environments are ideal for fostering innovation and problem-solving.   

5. Leverage existing materials & solutions 

Managing thermal energy is a challenge faced across various industries. While the specific applications can be very different, investigating these industries can reveal valuable insights and potential shortcuts to effective solutions.

Therefore, at the exploratory phase of the cell barrier project, our engineers begin by researching existing materials and solutions in industries such as consumer electronics, oil and gas, steel processing, and aerospace. This approach allows us to identify readily available materials with the desired properties, regardless of whether they have previously been used for the application.

6. High performance solutions are not one-size fits all

Every battery pack has unique requirements, with cell type, module, and pack design demanding different solutions. Prismatic, pouch, and cylindrical cells represent the primary cell types in use today, each requiring a tailored approach. While every solution must be customised to the specific needs of the battery pack, it can still utilise a core design framework.