In the context of the current climate crisis, sustainability goals are posing new challenges in the design and manufacture of batteries, a critical technology for the transition to a sustainable energy system. Against this backdrop, there is high demand for innovative technologies and designs for battery modules, especially in the automotive industry, which is currently shifting towards decarbonisation and electrification. Traditionally, battery module designs have focused on thermal and energy density requirements, with their mechanical design taking a back seat. However, recent studies have shown that pressure on the cells has a direct impact on their lifetime, which has led to the application of initial pre-compression and the use of foams to absorb cell swelling.
Despite these efforts, current solutions are unable to maintain constant pressure without adversely affecting energy density and cost. The ELASTBAT project proposes using thermoplastic elastomers (TPEs) in battery module compression plates, due to their recyclability, low density and flexibility. These materials could replace aluminium plates, maintaining uniform and constant pressure, reducing their weight and improving energy density and costs.
To design optimal TPE products, it is essential to consider their two-phase microstructure and the effects that processing has on their properties. ELASTBAT aims to develop an advanced process control method that combines intelligent control strategies with rheological simulations, optimising process variables to improve the performance and design of TPE products for battery modules.
In the ELASTBAT project, we will focus on developing advanced simulation and modelling methods designed specifically for TPE materials. These methods will not only consider the relationship between the microstructure and mechanical properties, but also the impact of the manufacturing process on these properties. Our goal is to identify process variables that can be measured online and have a significant impact on the final properties of products made with TPEs.
Specifically, we will be conducting research on:
- Developing a flexible TPE compression plate model that ensures that optimal pressure is exerted on the cells of a battery.
- Experimental procedures to determine the effect of processing, especially injection moulding, on the rheological, microstructural and thermo-mechanical properties of TPEs.
- Devising a simulation strategy to improve our understanding of the underlying mechanisms and to provide a clear insight into the effects of process parameters on morphological properties.
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