The increase in the energy density of batteries is adding to heat-related challenges. Thermal safety is highlighted both in the battery manufacturing process and in ready end products. For example, if the battery temperature suddenly rises too high or is subjected to a violent impact force, the situation may, at worst, even lead to the battery exploding.
Virtual modeling is an excellent tool for supporting design. Thermal simulation can be used to study the thermal behavior of the battery under genuine operating conditions and, based on the information obtained, the battery structure can be designed to minimize the risk of overheating.
The best results can be achieved by combining thermal simulation with mechanics simulation.
To the left of the image, the initial situation is shown, showing the overheating of battery cells. The solution was found through a simulation: a fan was added to the battery cells, a heat sink was added to the power electronics, and an insulating plate was inserted between the charging components and the batteries. On the right side is an image of the cooled cells.
We can use heat and flow simulations to model heat management during the use of battery cells. In addition, we can simulate cell cooling and determine the correct temperature measurement methods and locations from which measurements should be made.
Modeling drop and other situations where the battery is subjected to a sudden impact force ensures product safety. The simulation examines the effects of the impact on the battery and what structural changes need to be made in order to avoid the negative effects of the impact.
Assembly and tolerance modelling can be used to find the optimal solution for the battery structure. In practice, the benefit of the simulation can be seen in the fact that the battery can be made as small as possible.
The pressure test and the simulation of tightness requirements are used to examine the leakage and durability of the battery under pressure load. The practical benefit is to ensure water and dust tightness, as well as to design the optimal seal and determine its profile.
Certain types of batteries may swell when they fail due to, for example, the age of the battery, the way in which they are used, or the conditions within the operating environment. Swell modeling provides information that can be used in the mechanics design of a battery-powered device.
We do a wide range of material modelling, which means that we can virtually test how various materials function in the product. Simulation replaces expensive prototypes and saves time when you want to innovate with new materials.
Our specialists' expertise in vacuum and roll to roll technology, for instance, helps us understand the operating environment of the battery industry and the requirements it imposes.
In addition to simulations, our expertise extends to the following areas:
Finnish start-up Pulsedeon is developing next-generation lithium-ion battery solutions based on pulse laser coating technology (PLD) and other complementary technologies. Pulsedeon's method can be used to make solid electrolytes, protective films and thin layers of lithium metal, for example, which are otherwise difficult to implement.
Pulsedeon cooperates bilaterally with six major battery manufacturers in the development of batteries. It is also involved in EU battery projects.
Mectalent has collaborated fruitfully with Pulsedeon. The result of the collaboration was a prototype of Pulsedeon's innovated PLD device. We carried out the design and manufacture of the prototype for Pulsedeon as an easy turnkey service..
We design and manufacture customized and high-quality solutions for battery industry operators, from individual parts to advanced assemblies.
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