Materials for battery thermal management – optimizing performance, safety and lifespan
The development of high-performance lithium-ion batteries is one of the most important drivers of innovation in our time. Whether for electromobility, stationary energy storage, or industrial applications – modern battery systems must deliver ever higher energy densities, shorter charging times, and longer lifespans. At the same time, the demands on safety and reliability are increasing.
A crucial success factor is the thermal management of batteries. Only if the generated heat is reliably dissipated or distributed effectively can batteries consistently achieve their maximum performance. Dr. Dietrich Müller GmbH offers a comprehensive portfolio of thermal interface materials, insulation materials, and customized components that can be individually tailored to specific applications.
Why battery thermal management is so important
Lithium-ion batteries operate optimally only within a limited temperature range. Even slight temperature deviations can significantly affect their performance.
Excessive temperatures can lead to, among other things:
- accelerated aging of battery cells,
- reduced lifespan,
- declining performance,
- increased security risk.
Conversely, excessively low temperatures reduce charging and discharging power and significantly extend charging times.
A particularly critical factor is that individual cells within a battery module can heat up to varying degrees. If so-called hotspots develop, individual cells age faster than others. Therefore, homogeneous temperature management is essential for maintaining the long-term performance of the entire battery system.
Different applications require different material solutions.
Depending on the application, the requirements for thermal management vary considerably. Batteries for electric vehicles, stationary energy storage systems, or industrial applications place different demands on cooling, insulation, and mechanical protection.
Dr. Dietrich Müller GmbH develops individual solutions for this based on various material technologies:
- thermally conductive films,
- Thermal conductivity plates,
- Interface materials,
- thermal pastes,
- Gap pads,
- Phase-change materials,
- Electrically insulating thermally conductive materials.
The wide variety of materials allows solutions to be precisely adapted to the respective application.
Thermal conductive films and thermal conductive plates
Thermally conductive films and thermally conductive plates offer a particularly efficient way to transfer heat.
They improve heat transfer between battery cells, heat sinks, and housings, and significantly reduce the influence of insulating air layers. Modern materials achieve thermal conductivities of up to 9 W/mK, thus ensuring significantly improved heat dissipation. At the same time, they provide mechanical protection and can reduce vibrations or shock loads.
Depending on the application, different materials are available, for example:
- silicone sheets,
- Polyimide films,
- PEEK films,
- thermally conductive acrylic systems,
- thermally conductive polyester films,
- Foams with thermally conductive fillers.
Thermal pastes and phase-change materials
Not every application is suitable for solid interface materials. Thermal pastes or phase-change materials are frequently used for complex geometries or uneven surfaces.
These materials compensate for unevenness and improve thermal contact between components. Phase-change materials also store heat energy in the short term and help to reduce temperature fluctuations within the battery system.
Mechanical protection and electrical insulation
Besides heat transfer, modern materials fulfill other important tasks.
They serve, for example, as:
- Electric Isolation,
- Cell separator,
- spacers,
- Vibration damping,
- Protection against mechanical stresses,
- Barrier against leaking electrolytes.
The portfolio also includes special molded parts or epoxy plates for separating individual cell modules. This allows battery modules to be not only thermally optimized, but also made safer and more robust.
Future trend: Individually configured heat transfer solutions
The demands placed on battery systems are evolving rapidly. Higher energy densities, faster charging times, and more compact designs require increasingly efficient materials.
Current developments include, among others:
- ultra-thin high-performance films,
- thermally conductive adhesives,
- silicone-free thermal pads,
- High-temperature materials,
- PEEK and polyimide films,
- Highly thermally conductive gap pads.
In addition to standard products, customized solutions are becoming increasingly important. Individually tailored thermal interface materials facilitate assembly, reduce production times, and improve the quality of the assemblies.
Dr. Dietrich Müller GmbH as a development partner
Dr. Dietrich Müller GmbH has decades of experience in the processing of technical films, thermally conductive materials and electrical insulating materials.
The company supports its customers from material selection and design to series production and offers:
- technical advice,
- Configuration of individual heat conduction solutions,
- Stamped and molded parts,
- CNC machining,
- laser cutting,
- Waterjet cutting
- Custom-made packaging.
The combination of materials expertise and modern manufacturing results in solutions that are precisely tailored to the requirements of modern battery systems.
Summary: Key takeaways about intuitive eating
Thermal management in batteries is a crucial factor for the performance, safety, and lifespan of modern energy storage systems. Innovative thermal interface materials, thermally conductive films, thermally conductive plates, and insulation materials enable efficient temperature control while simultaneously protecting the sensitive battery cells.
With a broad portfolio of materials and extensive manufacturing expertise, Dr. Dietrich Müller GmbH supports manufacturers and developers in the realization of high-performance battery systems – from the initial idea to series production.
