Critical Sealing and Thermal Interface Material Solutions For Battery Systems

Critical Sealing & Thermal Interface Materials
Technology for Battery Systems
October 26th 2022 Dr. Amir Yazdani, Advanced Technology Development Manager
Automotive World Webinar Andreas Proksch, Product Manager Mobility
Contents
o Datwyler company introduction
o Datwyler mobility product portfolio
o Battery pack sealing solution
o Thermal interface material (TIM)
o Other sealing solutions
o Summary
Clear structure to increase market focus and
strengthen our core competencies
Pharma Mobility Connectors
Medical Food & Beverage General Industry
Healthcare Solutions Industrial Solutions

Online Distribution
Technology & Innovation
Finance & Shared Services
3 © Datwyler | www.datwyler.com
Global presence and manufacturing footprint
Pennsauken, US
Middletown, US Alken, BE Nový Bydžov, CZ
Vandalia, US
Twinsburg, US Cleebronn, DE
North Canton, US Karlsbad-Ittersbach, DE Yantai, CN
Daegu, KR
Jasper, US
Schattdorf, CH
Ontario, US
Wuxi, CN
Dallas, US
Pregnana Milanese, IT Ningguo, CN
Montgomery, US Viadanica, IT
Gray, US Dongguan, CN
Montegaldella, IT
Silao, MX
Querétaro, MX Kesurdi, IN
São Leopoldo, BR
Healthcare Solutions
Industrial Solutions
>1’000 >1’100 million >8’000 >25 >100 million

global customers & CHF yearly revenue associates production manufactured components
innovation leaders worldwide sites per day
Recognized core competencies as central element
for superior customer value
Material Solution
expertise design
From an …to a globally
innovative available serial
idea… Operational product.
excellence
Continuous Improvement
Serial Production
Design & Prototyping
Advanced Development
Sustainability highlights
Carbon neutrality by 2030: Already 38% of Foster diversity, equity and inclusion by Solar panels at Swiss and Indian plants.
electricity from renewable sources. launching a policy and council. Further plants in the planning stage.
Corporate Social Responsibility Founding member of Alliance to Zero, Proactive chemical

activities in India. a pharmaceutical supply chain initiative. compliance management.
Sustainability standards we comply with
UN Global Compact Global Reporting Initiative (GRI) Carbon Disclosure Project (CDP)
Membership since 2009 Sustainability reporting since 2008 Reporting since 2013
Specific ISO certifications Leading global ESG rating agency MSCI With the silver rating, Datwyler is in the top
14001, 50001, OHSAS 18001 awards Datwyler an "A" rating 15% of all companies assessed by EcoVadis
Mobility global production capabilities
Daegu, Korea
Cleebronn, Germany
Vandalia, USA
Schattdorf, Switzerland
Wuxi, China
Ontario, USA
Novy Bydzov, Czech Republic
Silao, Mexico Ningguo, China

Viadanica, Italy
Customized high-precision molding

Compounding & technical center
Mold shop
LSR, TPL São Leopoldo, Brazil
O-rings
Rubber-to-metal/plastic bonding
Lean & Clean manufacturing
Logistics center
8 © Datwyler, www.datwyler.com
Mobility product portfolio
Battery Systems Brake Systems
Brake Damping Piston Dust Boot

Battery housing Thermal Interface Cell electrode Membrane Disc Seal
seals Materials seals
Comfort Systems
Cabin Interior System
Dynamic Sealing Sliding

Seal Element Fork Arm
EAP control unit EAP Stack
Emission Reduction Systems
E-Powertrain
Equalizing Membrane SCR Fork Flutter

Housing gasket O-Ring DC Converter Element Valve
Powertrain
Electrification
Connection Spark Plug

Housings Boot
ADAS Fuel Systems
Camera Cap Radar System and Sensor Shell O-Ring CNG Sealing Disc
Power Connectors Seals Injector
Applications in battery system
Cell-level seals Battery module seals
EMI shielding
Thermal propagation barrier material
BCU/Electronics box seal

Battery pack foldable gasket
Standalone rubber seal
Cooling system connector seals

Active pressure/flow control valve
TIM/Thermal conductive sheet
Thermal conductive pads

HV/LV connector seals
Safety valve/pressure release seal

Novel cell monitoring
Flexible and
foldable joins
Foldable gasket
for battery pack
Battery pack seal solutions comparison
Battery Housing: Al, carbon fiber composite, reinforced plastic, steel,
etc.
Pack seal: Foldable gasket seal, pure rubber gasket, adhesive, etc.
Technical Requirements: IP6x, endurance, reliable installation.

electric conductivity, reopenable for inspection, etc.
Housing Sealing 1. Foldable Gasket 2. Pure Rubber Gasket Adhesive

Technology
Sealing Level- IP6x
Endurance
Electric Conductivity
Installation reliability
Reopenability
Foldable gasket
Benefits of Datwyler's Foldable Gasket
Effective control of tolerance

Integrated design of metal insert and rubber sealing
Reliable installation
Precise positing and mounting design
Reopenable for battery pack maintenance

Easy and efficient for inspection and maintenance
Good endurance
Reliable sealing and high bonding strength between metal insert and rubber
UL94 V0
In-house rubber material development
Electric conductivity and EMI shielding

Grounding of housing and shielding against electromagnetic interference
Customizable design
Co-engineering, design, and simulation
Foldable gasket – design optimization
Initial Design Foldable gasket
Battery housing
Foldable gasket metal insert
Stress concentrated in sealing lips, high

mounting force, air layer between
the housing and gasket
Improved Design
Green: Metal insert

Brown: Rubber seal
Optimized gasket dimensions and sealing

lip design to create close fit, improved
sealing performance, and mounting force
Novel light-weight
thermal interface
materials (TIM)
Cooling plate
Cell-module-pack
Thermal interface material (TIM)

Why thermal management
Why lithium-ion batteries
o Li-ion batteries have higher power and energy

density compared to other conventional chemistries
o Thus they are attractive in electric and hybrid electric
vehicle applications
Tian et al. (2020)
Challenges
o Safety issues related to the thermal runaway of Li-ion

batteries
o Degradation of internal components at higher temperatures
o Considerable heat generation due to charge and discharge
at high C-rates
o Poor performance at low temperatures
Photo courtesy of UL Reseach Institute
Thermal interface materials (TIM) for battery system
Various Thermal Interface Material solutions
o Conventional rubber pads

o Thermal gap fillers
o Thermal paste
o Adhesives
... Thermal Interface Material
These materials can be processed
o Cure-in-place glue, thermal form-in-place

o Molded or rolled thermal conductive pad, etc.
Thermal interface materials (TIMs) are designed to provide adequate

thermal conductivity to evacuate heat: performance longevity, safety
Source: https://www.youtube.com/watch?v=ssU2mjiNi_Q
Lightweight thermal interface materials (TIMs)
Thermal Conductivity vs. Density

The benchmark study:
7
State of the art TIM performance today: 6
Thermal Conductivity / W/mK

3.5 W/mK & 2500 kg/m3
5
4
Datwyler’s TIM technology:
1.0 – 5.0 W/mK & 1400 kg/m3 3
~ 44% reduced 1
weight
0 500 1000 1500 2000 2500 3000 3500 4000
Density / kg/m3
Datwyler offers state-of-the art cost-efficient TIM with a lower density leading to
~ 44% reduced weight
Battery heat-up during fast charging
Comparison of TIMs
TIM1 Material TIM2 Material

Thermal conductivity  = 1.0 W/mK Thermal conductivity  = 3.4 W/mK
Local T_max= 57.9 °C Local T_max= 52.2 °C

Steady-state after 36 min Steady-state after 29 min
TIM2 reached maximum temperature that was 6 °C lower and reached the steady state 7 minutes faster
Sealing solutions
for battery system
Successful case – HV connector battery socket seal
Successful case HV connector Battery socket seal
Dimension ~500X80 mm
− LSR
− High voltage
Requirement
− Electric insulation
− UL94 V0
Picture source: Gettyimages

✓ Co-engineering
✓ Simulation expert
Datwyler strength
✓ Reliable production
✓ Global footprint
Successful case – BCU box seals
BCU (battery control unit) box

Successful case
seal
Dimension ~100X100 mm
− Integrated design
− 3C (plastic-elastomer-plastic)
Requirement − High voltage
− Electric insulation
− UL94 V0
✓ Design co-engineering Picture source: https://group-media.mercedes-benz.com/

✓ Simulation expert
Datwyler strength
✓ Reliable production
✓ Global footprint
Other sealing solutions of battery systems
o Overmolded or o Seals for battery cell

separate seals e.g. electrodes (prismatic
for pressure relief and cylindrical)
safety valves
o Seals for cooling o Electrical connector

pipeline joints and seals (HV, LV, signal)
liquid cooling plates
Fuel cell
Addressing specific requirements for hydrogen-based technologies
Auxiliary Systems
o Development of application-specific
thermally conductive & EMI shielding
O-Ring materials
Air filter Fuel cell control unit Thermal
management
systems and o High performance elastomer parts for
other parts
Sealing disc reliable and durable performance of
Air compressor Electric
coolant pump auxiliary systems
Fuel Cell Stack
o Industrialization partner for bipolar
plates
Bi-polar plate
Key takeaways
o Datwyler's lightweight thermal interface materials ensure optimal operating temperature, increase
the battery's lifetime, and prevent thermal runaway events
o Datwyler's foldable gasket solutions for battery packs offers a reopenable alternative to adhesive
and rubber solutions
o Latest developments in component design and understand how design and simulation expertise
helps achieve an optimized solution
o Datwyler's co-engineering approach identifies technical challenges so that they can be understood
and overcome
Thank You!
For questions or scheduling
a meeting:
andreas.proksch@datwyler.com
amir.yazdani@datwyler.com

Critical Sealing and Thermal Interface Material Solutions For Battery Systems

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Critical Sealing & Thermal Interface Materials

Technology for Battery Systems

o Datwyler mobility product portfolio

o Battery pack sealing solution

o Thermal interface material (TIM)

o Other sealing solutions

Pharma Mobility Connectors

Medical Food & Beverage General Industry

Healthcare Solutions Industrial Solutions

Technology & Innovation

Finance & Shared Services

>1’000 >1’100 million >8’000 >25 >100 million

Corporate Social Responsibility Founding member of Alliance to Zero, Proactive chemical

Novy Bydzov, Czech Republic

Silao, Mexico Ningguo, China

Customized high-precision molding

Brake Damping Piston Dust Boot

Dynamic Sealing Sliding

Equalizing Membrane SCR Fork Flutter

Connection Spark Plug

ADAS Fuel Systems

BCU/Electronics box seal

Cooling system connector seals

Thermal conductive pads

Safety valve/pressure release seal

Technical Requirements: IP6x, endurance, reliable installation.

Housing Sealing 1. Foldable Gasket 2. Pure Rubber Gasket Adhesive

Effective control of tolerance

Reopenable for battery pack maintenance

Electric conductivity and EMI shielding

Stress concentrated in sealing lips​, high

Green: Metal insert

Optimized gasket dimensions and sealing

Thermal interface material (TIM)

o Li-ion batteries have higher power and energy

Tian et al. (2020)

o Safety issues related to the thermal runaway of Li-ion

Photo courtesy of UL Reseach Institute

o Conventional rubber pads

These materials can be processed

o Cure-in-place glue, thermal form-in-place

Thermal interface materials (TIMs) are designed to provide adequate

Thermal Conductivity vs. Density

Thermal Conductivity / W/mK

TIM1 Material TIM2 Material

Local T_max= 57.9 °C Local T_max= 52.2 °C

Successful case HV connector Battery socket seal

Picture source: Gettyimages

BCU (battery control unit) box

✓ Design co-engineering Picture source: https://group-media.mercedes-benz.com/

o Overmolded or o Seals for battery cell

o Seals for cooling o Electrical connector

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Stress concentrated in sealing lips, high