IsoFoamComp
The risk of battery fire is one of the major drawbacks that discourages many potential users from using battery storage and their applications. The goal of this project is the developing of a novel composite material consisting of an aluminum foam component and a thermally switchable polymer layer which is able to passively control the temperature of the cells and modules. Moreover, in the event of thermal runaway the composite forms an insulation layer that protects adjacent cells and modules.
Project Partners
- Isovolta AG, Austria, Coordinator
- Fraunhofer Institute for Machine Tools and Forming Technology (IWU), Germany
- Association Pour L´Environnement Et La Securite En Aquitaine (APESA), France
- Polymer Competence Center Leoben GmbH
Motivation and Goals
Increasingly stringent emission standards for CO2 and nitrogen oxides in motor vehicles can only be achieved by expanding electro mobility. However, battery-powered vehicles are at risk of thermal runaway and thermal propagation in the event of an accident or short circuit in the battery pack.
In the project, a hybrid, functional composite material in sandwich construction (IsoFoam-Composite) is to be developed to contain and reduce thermal runaway / thermal propagation (target TRL 4). The goal is to prevent the module from burning through to the passenger cell, and at the very least to increase the time until the battery box burns through by 50 %. In addition to fire protection through the use of ceramifying polymers and intumescent fillers, additional functions such as passive cooling through phase change material (PCM), electromagnetic shielding (EMI shielding) and protection against mechanical impact on the battery cells are to be integrated.
The required properties are realized through the targeted development of tailored components consisting of a functional composite material for thermal and electrical insulation (IsoFoam-PolyMica) and functional aluminum foam components (IsoFoam-Al) for mechanical properties and passive thermal management (start TRL 2).
Expected impacts of the project results are for example increasing the safety of battery applications and supporting the targets regarding greenhouse gas emission reduction due to the reduction of energy needed for tempering battery systems by passive cooling applications. The novel composite material can lead to a strengthened industrial leadership as well as a strengthened innovation excellence of the European academia and research institutes in the field of material development for battery applications.
Main Goals
- Evaluation of the module component and creation of specifications
- Development of functional, thermally switchable insulation composites, optimizing the layer structure and joining concepts
- Development of an aluminum foam composite and joining technology
- Production of the final product on pilot-plant scale
- Thermo-mechanical characterization of the developed composites
- Study of the module testing and validation
- Life cycle assessment (LCA)
Objectives and Approach
- Creation of a battery module cover from new materials, benchmark against production-ready materials. Analysis of batteries in case of failure
- Development of tailor-made polymer materials and filler systems with intumescent and ceramifying properties
- Combination of these materials with mica-based sheets to create IsoFoam-PolyMica composite with switchable thermal conductivity while maintaining electrical insulation
- Development of function-integrated aluminum foam sandwiches (IsoFoam-Al) with high specific strength, stiffness and passive thermal management via integrated PCM in the pore structure
- Selection and developing of joining techniques for integrating materials into a IsoFoam-Composite
- Thermal and mechanical characterization of individual materials and final composite
- Ensuring that the developed composite is economically producible for large-scale use
- Conducting LCA to compare ecological impact and show added ecological value over existing solutions
“IsoFoamComp project aims to enhance battery application safety and support greenhouse gas emission reduction by reducing energy use for tempering through passive cooling, while strengthening industrial leadership and innovation excellence in European research on battery material development.”
Funding Body
This project is performed within the M-ERA.NET 3 network (project-no: 10210) and funded by the following funding organizations: Federal Ministry for Innovation, Mobility and Infrastructure (BMIMI) managed by the FFG – Austrian Research Promotion Agency (project-no FO999903370, Saxon State Ministry for Science, Culture and Tourism of the Free State of Saxony, Germany (SMWK) and Région Nouvelle Aquitaine, France (RNAQ).
