Evaluation of the thermal pad behavior in the design and manufacture of lithium-ion battery packs in electric vehicles

The effective thermal management of lithium-ion (Li-ion) battery packs in electric vehicles (EVs) is critical for ensuring their performance, safety, and longevity. This paper evaluates the behavior of thermal interface materials (TIMs) in the design and manufacture of these battery packs, focusing on the use of thermal pads. An ideal TIM must balance multiple characteristics: high thermal conductivity, excellent electrical insulation, flame retardancy, flexibility, minimal thickness, non-toxicity, non-reactivity/non-corrosiveness, ease of installation and removal, low cost, and long-term stability. However, achieving a TIM that meets all these criteria simultaneously is challenging due to the trade-offs involved. This study proposes a TIM with high thermal conductivity and assesses its efficiency through simulation using Ansys Fluent software. The simulation results demonstrate that the proposed TIM maintains the battery cells within the acceptable temperature range, confirming its effectiveness in heat transfer for this application. The findings underscore the potential of the proposed TIM to enhance the thermal management of Li-ion battery packs in EVs. The paper also includes a comprehensive literature review, methodology for TIM selection and simulation, and a detailed evaluation of the simulation results.