Battery cells are the basic unit that produces energy in every battery. Electric vehicle (EV) batteries must be shock resistant and able to withstand extreme temperature fluctuations (both high and low).
A battery module contains a stack of battery cells that are mounted in a frame. The module has the task of protecting the cells from heat and vibrations.
Battery packs are built from battery modules together with control systems (e.g. battery management system (BMS)) and protection systems (e.g. cooling system).
When batteries are charged, they generate heat that must be removed from the battery. Overheating can cause a battery to lose its lifespan and performance.
One solution for effective heat transfer in battery cells, modules, and packages is punched interface materials. Dr. Dietrich Mueller GmbH produces such components (gap pads, phase change, and graphite) in order to avoid heat problems and to extend the service life of the battery.
The Dr. Dietrich Mueller GmbH ensures that the safety of batteries and EVs in cells and modules can be guaranteed by preventing and suppressing the spread of heat. Dr. Dietrich Mueller GmbH converts various materials that are both flame-proof and meet the requirements of Underwriter Laboratories (UL). For example 3M FRB and BISCO silicone foams.
Gaskets and seals
The seals are decisive for the operation of battery modules and battery packs. The upper and lower housings often enclose a battery module or pack. The protection of the sensitive components from the ingress of air, dust and water is ensured by a seal between the two housings.
The seal not only keeps unwanted elements out, but also keeps dangerous substances in the battery in the event of a collision. Sealing materials must withstand extremely high temperatures and often have to pass vertical and horizontal tests with a flammability class of UL94 V-0.
Dr. Dietrich Müller GmbH is able to help with the selection of suitable materials. We have strong business relationships with raw material suppliers such as Koepp, 3M, Zote Foam, Armacell, Rogers Corporation and others.
PORON urethane and Rogers BISCO silicone have excellent compressive and solidification properties and have proven themselves under extreme temperature conditions. This makes them ideal materials for making EV gaskets and gaskets.
Double-coated tapes such as 3M VHB are suitable for joining and gluing materials and seal against moisture and dirt.
Dielectric barriers and insulators
In order to meet the safety requirements for electrical barriers and insulation, flame arresters and materials with dielectric barrier properties are integrated into the components of batteries. Often these materials have a double function, which serves as thermal insulation and barrier at the same time.
These materials must be light, flame retardant and adaptable to meet the requirements of the application in question. Dr. Dietrich Mueller GmbH uses such materials (including ITW Formex, Lexan films, polyimide films, and 3M EMI / EMC materials) to manufacture customer-specific battery components.
Spacers and compression pads
The spacers and compression pads of a battery module must hold the cells in place. They need to be firm enough to accomplish this, while at the same time being able to maintain compression as the cell expands and contracts.
Spacers and thrust pads require sustained performance even under extreme conditions and temperature ranges. Dr. Dietrich Müller GmbH is one of the leading processors for various foams for pressure pads. These include: Rogers PORON polyurethane, Rogers BISCO silicone foam together with neoprene-based foams.
Rogers PORON and BISCO are great solutions for battery cell compression pads because they offer the reliability of stress relaxation and compression set resistance over a wide temperature and temperature range. As demonstrated in NVH and BSR tests, foam pads also provide isolation and dampening of the noise and vibration that arise when a vehicle is operated.
The performance of vehicle electronics and batteries can be maximized by protecting against electromagnetic interference (EMI). Operating a battery and connecting battery cables can often create a large EMC field that can affect the other electronics in the vehicle.
Conductive elastomers, seals, foils, adhesive components that are pressure sensitive can help with EMC shielding. The Dr. Dietrich Mueller GmbH uses such products in the manufacture of parts for the manufacture of batteries.