Test stand for evaluating a material used in a battery, and method using such a test stand
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- HENKEL KGAA
- Filing Date
- 2025-11-10
- Publication Date
- 2026-06-11
Smart Images
Figure EP2025082469_11062026_PF_FP_ABST
Abstract
Description
[0001] Henkel AG & Co. KGaA September 22, 2025
[0002] “Test stand for the evaluation of a material used in a battery and methods using such a test stand”
[0003] Description
[0004] The invention relates to a test rig for evaluating a material suitable for use in a battery under conditions such as those that can occur during a thermal runaway of a battery cell. The invention further relates to a method in which the test rig is used.
[0005] High-voltage batteries are used in numerous applications today, particularly in the field of electromobility. For this purpose, individual battery cells are assembled into larger battery arrays. The individual battery cells, often with a circular or rectangular base, are arranged close together in a battery housing and connected in series and / or parallel.
[0006] A local short circuit between the internal electrodes of a battery cell leads to a high short-circuit current, which heats the affected battery cell to extreme temperatures in a short time. External mechanical damage or thermal overheating, for example due to a battery cooling system failure, can also lead to extreme heating or thermal runaway of the battery cell. This thermal runaway can easily and rapidly spread to neighboring battery cells. This triggers a chain reaction in which the energy stored in the battery is released explosively. This explosive energy release, also known as thermal propagation, can be accompanied by toxic gases, flames, and sparks, and therefore poses a significant risk to people and the environment.
[0007] It is known from the prior art to use a material with low thermal conductivity, high dielectric strength, and high thermal (fire) resistance between the individual battery cells to reduce the risk of thermal propagation. For example, EP 3 753 056 B1 discloses embedding the individual cylindrical battery cells in a potting compound consisting of a polyurethane foam with a high proportion of flame retardant. The polyurethane foam should ideally have a flame resistance rating of V0, as measured according to the UL 94 test for the flammability of plastics.
[0008] The UL 94 test, frequently used in the automotive industry to evaluate fire-resistant materials, is conducted with an open flame. The classification determined during the test (for example, level V0) indicates the suitability of a material for the 2024PF00199
[0009] 2
[0010] Testing materials in a battery with the aim of minimizing thermal propagation has limited significance, as the test conditions differ considerably from those found in a battery. Therefore, materials such as flame-retardant coatings and potting compounds are also tested in batteries where thermal runaway of a battery cell is initiated. However, this is done using non-standardized setups or methods, as each battery manufacturer uses its own battery design and test setup. Consequently, the test results obtained from an initiated thermal runaway are not directly comparable.
[0011] From EP 4 432 418 A1 and US 2018 / 095139 A1, a test rig for evaluating the potting compound in which the individual battery cells are embedded is known. The test rig has a housing. Inside the housing are an initiation cell and several neighboring cells arranged near the initiation cell. The initiation cell can be activated to initiate thermal runaway of this cell. The test rig can be used, for example, to investigate the extent to which thermal propagation can be prevented by the potting compound used.
[0012] An initiation cell, designed as a battery cell, can be initiated or activated in various ways. One method is to overcharge the initiation cell or subject it to an excessively high charging current. Internal safety measures, such as those used in high-voltage automotive batteries, which automatically terminate charging in case of overcharging or overcurrent, prevent this activation method or would require complex circumvention.
[0013] Alternatively, the initiating cell can be heated by an externally applied heating element to initiate thermal runaway. However, there is a risk that the heating element will also activate one or more adjacent neighboring cells, meaning that thermal runaway of multiple cells cannot be ruled out. This is problematic for evaluating thermal propagation, as it is unclear whether damage to a neighboring cell is due to multi-cell runaway or solely to thermal propagation. Furthermore, it has been found that the test results are only partially reproducible in this case.
[0014] Finally, the initiation cell can also be activated by mechanical damage, for example, by a nail driven into it. For this to occur, the initiation cell must be easily accessible from the outside. This necessitates that the initiation cell be positioned at the edge or outer edge of the test stand housing, rather than in a central position. However, in an outer position, the initiation cell is located in close proximity to a housing wall of the test stand. Due to the heat capacity and thermal conductivity of the housing wall, this close proximity leads to unrepresentative- 2024PF00199
[0015] 3 test results that are difficult to extrapolate to the conditions of a real battery.
[0016] The invention is therefore based on the objective of providing a test setup for a material that can be used in a battery, which ensures a good balance between effort (costs, time, test environment) and benefit (reproducibility, transferability to batteries) with regard to material evaluation in the event of thermal runaway.
[0017] The problem underlying the invention is solved by the subject matter according to claim 1. Exemplary embodiments can be found in the dependent claims to claim 1.
[0018] According to the invention, a heating element is arranged on a lateral surface of the initiation cell, extending in the circumferential direction of the initiation cell only over a first partial region of the lateral surface. This first partial region faces a first neighboring cell. A second partial region of the lateral surface is free of a heating element arranged on the lateral surface and faces a second neighboring cell. The first neighboring cell is in a (deeply) discharged state, while the second neighboring cell is in a charged state.
[0019] The first neighboring cell, which faces the heating element of the initiating cell and is therefore located close to it, is also heated when the initiating cell is activated. However, since this first neighboring cell is (deeply) discharged or barely charged, the risk of thermal runaway occurring in this cell is low. This ensures that only one battery cell, namely the initiating cell, can be considered the starting point for thermal propagation. This increases the reproducibility of the test results.
[0020] The second neighboring cell, which is not located near the heating element, experiences virtually no heating from the heating element. Should a defect also be detected in the second neighboring cell after the test run, this is due to overheating caused solely by thermal propagation, which was initiated by the initial thermal runaway of the initiating cell.
[0021] Due to the low state of charge of the first neighboring cell, the probability is small that the thermal runaway of the initiating cell and thermal propagation will also cause the first neighboring cell to thermally runaway, thereby releasing a significant amount of energy and contributing to thermal propagation. Compared to a battery with cells that all have a fully charged state of charge, the probability of thermal propagation will therefore tend to be lower in the test setup. On the other hand, the test setup according to the invention with a discharged second neighboring cell meets the requirements of 2024PF00199
[0022] The temperature distribution in a battery is significantly closer than in a test setup where the initiating cell is positioned directly against the casing wall. Since the casing wall is typically made of metal, a significant amount of heat dissipates through it, which has a considerable impact on thermal propagation.
[0023] The second neighboring cell can be fully charged, with the resulting full charge corresponding to the maximum capacity. The first neighboring cell can be completely discharged or deeply discharged, so that no residual charge remains (state of charge corresponds to 0% of the maximum capacity). In one embodiment, the initiating cell and all neighboring cells—with the exception of the first neighboring cell or cells—are charged to at least 95% or preferably to 100%.
[0024] The initiation cell can have a circular cross-section. The neighboring cells can also have a circular cross-section. For example, the diameter of the circular cross-section can be 15 to 50 mm. The height of the initiation cell and / or neighboring cells can be 60 to 100 mm. Preferably, the shape and size of the initiation cell and the shape and size of the neighboring cells are identical.
[0025] The initiation cell can also have a rectangular cross-section or base. If the cross-section of the initiation cell is rectangular, the cross-sections of the neighboring cells can also be rectangular. The cross-section or base of the initiation cell can also be enclosed by any closed curve (for example, an oval curve).
[0026] In one embodiment, the heating element extends essentially over the entire height of the initiation cell. For example, if the initiation element is 70 mm high, the heating element will also have a height of 70 mm or a slightly smaller height (for example, 63 to 70 mm, i.e., greater than or equal to 90%). When the heating element extends over the entire height of the initiation cell, a comparatively large amount of heat can be supplied to the initiation cell from the outside per unit of time.
[0027] The initiating cell and the neighboring cells can be arranged in a honeycomb pattern, with the initiating cell located in the center and six neighboring cells arranged around it. In this embodiment, the test setup thus has a total of seven cells or battery cells. The neighboring cells are preferably located at the vertices of an equilateral hexagon with a side length corresponding to a distance A between the initiating cell and the neighboring cell. Preferably, in this embodiment, the initiating cell and the neighboring cells each have the circular cross-section mentioned above. 2024PF00199
[0028] 5
[0029] In the embodiment with the honeycomb pattern, four neighboring cells can be charged, while two neighboring cells are uncharged. Thus, the test setup would have two first neighboring cells (uncharged) and four second neighboring cells (charged). The two uncharged first neighboring cells are preferably arranged directly adjacent to each other, so that they form an equilateral triangle with side length A together with the initiation cell located in the center of the honeycomb pattern. The heating element is arranged between the initiation cell and the two first neighboring cells.
[0030] The first sub-area can correspond to 20 to 50% of the total circumference of the lateral surface when viewed circumferentially. For example, if the initiation cell has a circular cross-section or a circular base with diameter D, the total circumference would be TT x D. The first sub-area would then have a length of 0.2 x TT x D to 0.5 x TT x D when viewed circumferentially. For an initiation cell with a circular base, it is also convenient to specify the extent of the first sub-area in degrees when viewed circumferentially. For example, the first sub-area can extend within an angular range of 60 to 150°, preferably 80 to 130°.
[0031] It is also possible that the cells of the test rig according to the invention are arranged in a row. The initiation cell is positioned between exactly two neighboring cells, namely between the first neighboring cell and the second neighboring cell.
[0032] The heating element can be a flat heating element. It can be designed as a heating film or heating mat. Preferably, the heating element converts electrical energy into heat energy. The heating element can have an electrical power consumption of 40 to 150 W. The total surface area of the heating element can be 10 to 50 cm². 2 be.
[0033] The housing of the test stand can be made of metal, for example, steel or aluminum. In one embodiment, the housing comprises a circular base plate. A cylindrical side wall can extend from the circular base plate to an upper edge to which a housing lid can be attached. The interior volume of the housing can be in the range of 200 cm³. 3 up to 800 cm 3 lay.
[0034] A further object of the invention, namely the provision of a method for evaluating a material usable in a battery under conditions such as those that can occur during thermal runaway, is achieved by the combination of features according to claim 9. This method utilizes the test rig described herein according to the invention. The method according to the invention provides that electrical energy is supplied to the heating element to activate the initiation cell. 2024PF00199
[0035] 6
[0036] The initiation cell can be fully charged before or during the supply of electrical energy. In one embodiment, the initiation cell is already fully charged when heating by the heating element begins.
[0037] The invention will be explained in more detail with reference to an embodiment shown in the drawing. The drawing shows:
[0038] Figure 1 schematically shows a test rig in cross-section; and
[0039] Figure 2 shows the test setup of Figure 1 in longitudinal section.
[0040] Figures 1 and 2 show a test stand, designated as 1 in its entirety. The test stand 1 comprises a housing 10 with a circular base plate 11 and a circumferential cylindrical side wall 12. A removable housing cover 14 rests on an upper edge 13 of the side wall 12 and can be attached to the side wall 12 by suitable fasteners (not shown).
[0041] The casing 10 encloses an interior space 15 in which several battery cells, or cells 20, are arranged. The cylindrical cells 20 each have a circular base 21 with a diameter D. All cells 20 are identical in shape, size, and construction. The height of a cell 20g is designated H. The cells 20 are arranged in a honeycomb pattern. An initiation cell 20a, located in the center of the honeycomb pattern, is surrounded by six neighboring cells 20b to 20g.
[0042] The six cylindrical neighboring cells 20b to 20g lie with their respective central axes on the vertices of a virtual regular hexagon 22, wherein a length of an edge of the hexagon 22 corresponds to a distance A between two adjacent neighboring cells (for example 20f and 20g) or the distance A between the initiating cell 20a and each neighboring cell 20b to 20g.
[0043] The group of neighboring cells 20b to 20g comprises two first neighboring cells 20b and 20c, which are completely or almost completely discharged. Their state of charge is therefore exactly 0% or approximately 0% of the maximum capacity of each cell 20. The first neighboring cells 20b and 20c are directly adjacent to each other and, together with the initiating cell 20a, form an equilateral triangle with side length A.
[0044] Furthermore, the group of neighboring cells 20b to 20g includes four second neighboring cells 20d to 20g, which, unlike the first neighboring cells 20b and 20c, are fully charged. Their state of charge thus corresponds exactly to 100% or approximately 100% of their maximum capacity. 2024PF00199
[0045] 7
[0046] The initiation cell 20a is also in a fully charged state. Alternatively, it is also possible that the charge level of the initiation cell 20a is only close to 100%, but will only be charged to 100% in a test procedure, which will be described in detail below.
[0047] A planar heating element 30 is arranged on a lateral surface 23 of the initiation cell 20a, which is, for example, glued to the lateral surface and fixed to it in another suitable manner. The lateral surface extends over the entire height H of the initiation cell 20a.
[0048] Perpendicular to the height H, i.e., in the circumferential direction, the heating element 30 extends only in a first sub-region 24 of the lateral surface 23. A second sub-region 25, which corresponds to the total circumference of the lateral surface 23 minus the first sub-region 24, does not contain a (further) heating element. The second sub-region is therefore free of a heating element.
[0049] In the embodiment shown here, the heating element 20 extends circumferentially over an angular range characterized in Figure 1 by angle 26. Angle 26 is approximately 120°. In its flat or unwound state, the heating element 30 assumes the shape of a rectangle, with the length of one edge of the rectangle corresponding to the height H and the length of the other edge corresponding to the circumferential extent of the heating element.
[0050] The first section 24, or heating element 30, faces the first two neighboring cells 20b and 20c. In other words, the first neighboring cells 20b and 20c are directly adjacent to heating element 30. No heating element is provided between the second neighboring cells 20d to 20g and the initiation cell 20a.
[0051] In Figure 1, reference numeral 16 denotes an upper edge of a potting compound in which the cells 20 are embedded. The potting compound can be a foamed polyurethane. Above the potting compound, i.e., between the upper edge 16 and the cover 14, another potting compound or a top layer can be provided.
[0052] Figure 1 further shows several openings 17, 18 in the side wall 12. Through the openings 17, conductors can be routed from the outside into the interior 15, for example, to transmit signals from thermocouples in the interior 15 of the housing 10. Conductors for supplying power to the heating element 30 or—if necessary—for charging the initiation cell 20a can also be routed through the openings 17. The openings 18 are representative of ventilation openings in the housing, which could also be provided, for example, in the housing cover 14.
[0053] The following is a brief description of a possible test procedure and the associated test preparations: 2024PF00199
[0054] 8
[0055] First, the heating element 30 is attached to the one of the seven cells 20 designated as the initiation cell 20a. The heating element 30 is supplied with power cables. Furthermore, the initiation cell 20a and the other cells 20b to 20g can be equipped with thermocouples. The initiation cell 20a is connected to charging cables to allow charging of the initiation cell 20a during the test procedure.
[0056] After wiring is complete, the seven battery cells 20 are placed together in the housing 10. The assembly may include cell holders (not shown here) which define the honeycomb pattern described above. Two uncharged neighboring cells 20b and 20c are positioned so that they face the heating element 30 of the centrally positioned initiating cell 20a. All other neighboring cells 20d to 20g are 100% charged.
[0057] After inserting the assembly into the housing, the potting compound is poured in. This fixes the individual cells 20 within the housing. If the potting compound is an expansive material, it only needs to be poured to half the height of the cells 20 now located in the interior 15 of the housing. Due to the expansive action, the potting compound rises to the upper edge 16. The remaining space between the upper edge 16 and the upper edge 13 of the side wall 12 can be filled with another layer of potting compound. The cover 14 is then attached to the side wall 12, and a sealant may be applied between the cover 14 and the upper edge of the side wall.
[0058] Once all cables and wires leading from housing 10 have been connected to the power supply or to the devices receiving the measurement signals, the actual test can begin. An electrical voltage, for example 20 to 60 volts, is applied to the heating element 30. This heats the initiation element 20a until thermal runaway of the initiation cell is triggered. During this process, the temperatures inside housing 15 are continuously recorded at various locations via thermocouples. The thermocouples can measure the temperature at different points on or inside housing 10 (for example, in the potting compound, on the inside of the cover 14, above the cell contacts). By evaluating the various temperature profiles and inspecting the individual cells 20a to 20g after the test is completed, it can be determined whether and to what extent thermal propagation has occurred.The test results obtained allow conclusions to be drawn about the suitability of the battery safety materials used to prevent thermal propagation and reduce the risk in the surrounding area. 2024PF00199.
[0059] Reference symbol list
[0060] 1 Test stand
[0061] 10 cases
[0062] 11 Base plate
[0063] 12 side wall
[0064] 13 upper edge
[0065] 14 Case covers
[0066] 15 Interior
[0067] 16 upper edge of the potting compound
[0068] 17 Opening
[0069] 18 Opening
[0070] 20 cells / battery cells
[0071] 20a Initiation cell
[0072] 20b, 20c first neighboring cell
[0073] 20d - 20g second neighboring cell
[0074] 21 Base area
[0075] 22 Hexagon
[0076] 23 Surface area
[0077] 24 first sub-area
[0078] 25 second sub-area
[0079] 26 angles
[0080] 30 heating elements
Claims
2024PF00199 10 Patentansprüche 1. Test rig (1) for evaluating a material usable in a battery under conditions such as those that can occur during thermal runaway, wherein the test rig (1) comprises a housing (10), an initiation cell (20a) and several neighboring cells (20b to 20g), wherein the material to be evaluated is arranged in an interior (15) of the housing (10) or on the housing (10), wherein the initiation cell (20a) with a lateral surface (23) and the neighboring cells (20b to 20g), which are arranged near the initiation cell (20a), are located in the interior (15) of the housing (10), characterized in that a heating element (30) is arranged on the lateral surface (23) of the initiation cell (20a), which extends in the circumferential direction of the initiation cell (20a) only over a first partial region (24) of the lateral surface (23), wherein the first partial region (24) is facing a first neighboring cell (20b, 20c),wherein a second sub-area (25) of the lateral surface (23) is free of a heating element arranged on the lateral surface (23) and faces a second neighboring cell (20c to 20g), and wherein the first neighboring cell (20b, 20c) is in a discharged state and the second neighboring cell (20c to 20g) is in a charged state.
2. Test stand (1) according to claim 1 , characterized in that the first neighboring cell (20b, 20c) is completely emptied and the second neighboring cell (20c to 20g) is completely charged.
3. Test stand (1) according to claim 1 or 2, characterized in that the initiation cell (20a) has a circular cross-section or a rectangular cross-section.
4. Test stand (1) according to one of claims 1 to 3, characterized in that the heating element (30) extends substantially over the entire height (H) of the initiation cell (20a).
5. Test stand (1) according to one of claims 1 to 4, characterized in that the initiation cell (20a) and the neighboring cells (20b to 20g) are arranged in a honeycomb pattern in which the initiation cell (20a) is arranged in a center and six neighboring cells (20b to 20g) are arranged around the initiation cell (20a), wherein the neighboring cells (20b to 20g) are located on the corners of an equilateral hexagon (22) with a side length corresponding to a distance (A) between the initiation cell (20a) and the neighboring cell (20b to 20g). 2024PF00199 11 6. Test stand (1) according to one of claims 1 to 5, characterized in that the first sub-area (24) corresponds to 20 to 50% of the total circumference of the lateral surface (23) when viewed in the circumferential direction.
7. Test stand (1) according to one of claims 1 to 6, characterized in that the heating element 0 is designed as a heating film or heating mat.
8. Test stand (1) according to one of claims 1 to 7, characterized in that the housing (10) comprises a circular base plate (11).
9. Method for evaluating a material that can be used in a battery under conditions such as may occur during thermal runaway, wherein the method provides for the use of a test stand (1) according to any one of claims 1 to 8, wherein electrical energy is supplied to the heating element (30) to activate the initiation cell (20a).
10. Method according to claim 9, characterized in that the initiation cell (20a) is fully charged before or during the supply of electrical energy.