The mobility industry, under intense time and cost pressure, is striving to bring battery electric vehicles to market more affordably.

Lower costs are crucial for the swift launch of sustainable mobility. Amidst increasing energy densities in vehicle batteries, the importance of battery safety is rising. As the EVS-GTR and legal requirements for high-voltage battery systems are being coordinated, controlling thermal runaway becomes crucial. Meeting growing safety standards efficiently and cost-effectively is a major challenge for the industry, requiring the establishment of new methods for a holistic safety assessment, currently lacking in the industrial development process.

Main Objectives of Tri-State

The main objective of this project is to develop and test an interdisciplinary evaluation method for battery systems for the holistic assessment of thermal safety. The assessment method involves linking the three disciplines of thermal management, thermal runaway and crash.

The following sub-goals are derived:

1. a newly developed evaluation method and the associated significant cost and time savings for the industrial partners in the development process

2. the development, testing and evaluation of new safety concepts with the developed method

3. the development of proposals for new combined thermal-mechanical test procedures

Main Results

New Cooling Approaches

Combined multiphysical approach for “cylindrical cells with direct cooling” and for “pouch cells with indirect cooling”

New Thermal Concepts

New thermal safety concepts (coolant, control strategies, sensors) for both use cases under consideration

Thermal-Mechanical Test Procedures

Proposals for combined thermal-mechanical test procedures that can be submitted to various committees