EV Batteries and Energy Storage

Energy storage applications and electric vehicle batteries operate in some of the world’s most demanding and extreme environments. To prolong safe and reliable battery performance at maximum efficiency, designs must be strategically ruggedized to protect against extreme heat, cold, UV exposure, wind, sand, rain, road vibration, and sudden impact.

Having an adequate seal for packs and modules protects the battery and its cells against liquid, gas, particle, and contaminant intrusion or exposure to prevent catastrophic failures and prolong battery life.

Batteries need to be protected against sudden impact, vibration, and swelling forces that can come from mechanical movement, temperature cycling, sound, wind, or other environmental factors. Electric vehicle batteries experience additional extreme environments from harsh road conditions and collision impact from accidents and near-misses.

Boyd’s compression pads layer between battery cells to compensate for swelling forces, manage cell expansion and contraction of cell tolerance stack, and act as an impact protection barrier from mechanical movement resulting from collisions and vibration. Ruggedized impact-absorbing battery seals help you minimize the detrimental impact to batteries and reduce maintenance demand and consumer warranty costs while enhancing battery safety.

Batteries are the most integral part of an electric vehicle or energy storage installation with charge cycling, storage capacity, and range being a primary concern to adoption. Thermal density limitations are often a key contributing factor to innovation in this space. Boyd’s liquid cooling systems and cold plates enable smaller, lighter battery thermal systems; creating more design space for more powerful batteries with faster charge cycles and more efficient utilization of energy. Electric vehicles specifically benefit from EV batteries that are more reliable and have greater driving range per charge.

Modern battery design is optimized to prevent fire from ever occurring. But in the rare event of a catastrophic battery failure with fire, proactive safety design integrates high performance and reliable fire isolation. Fire isolation can be achieved many different ways and at different battery system levels for primary and secondary fire isolation performance. Battery cells and modules can be wrapped with electrically isolating high performance films. These lightweight, rugged insulation layers wrap battery cells to prevent spart voltage between internal critical components that can lead to device shorting or fire. Using the highest flame-rated FR V0 isolation films helps to prevent fire from occurring, or isolating it at the primary battery cell level in the unlikely event a cell combusts.

SOLIMIDE® is a fire resistant, ultra-lightweight, non-toxic foam that can maintain peak performance at both high and low temperature extremes. It is exceptionally flame resistant and used as a flame barrier in many critical applications. SOLIMIDE® will not ignite or combust under continuous long term direct exposure to flame, emits zero toxins and very little smoke. It offers traditional foam performance characteristics like compressibility and vibration damping. It’s also non-wicking with high hydrolytic stability, meaning it won’t retain water or water weight and can withstand long exposure to liquids. When applied in a battery pack, it acts as secondary fire protection at the battery pack level, isolating flame and fire while absorbing both mechanical vibration and acoustics for safer, quieter, more reliable batteries.

Good temperature management of lithium-ion battery cells with additional back up safety features help to prevent battery thermal runaway events or respond safely and swiftly if they occur. Thermal runaway prevention starts with optimized design but also requires components that protect against thermal runaway propagation. Multi-functional, complex battery component solutions designed for cell-to-cell application absorb impact, vibration and movement, dissipate cell heat, and act a flame or heat barrier and isolator if a catastrophic event were to occur. Enable your designs to proactively and safely prevent thermal runaway events by managing vibration, movement and friction, and quickly isolate extreme heat or fire in the unlikely event battery safety design features fail to prevent cell-to-cell propagation. Highly integrated thermal runaway prevention assemblies feature cooling fins or heat spreaders with compression pads and flame-rated electrical insulation to isolate li-ion battery cells. Prevent, protect, and isolate battery storage thermal runaway and EV battery thermal runaway.

Boyd Corporation maintains 40+ ISO 9001 and nine IATF 16949 certified manufacturing operations across three continents to assure our energy storage and eMobility components exceed the rigorous demands for quality management systems with adept regional support. Boyd’s customer focus and relationship management culture are aligned with the most demanding QMS system processes. By optimizing processes, organization, and efficiency, we reduce costs, increase yield rates with effective management and assembly processes, all while providing our customers the highest quality products.

Boyd’s globally available, in-region ISO 14001 certified manufacturing operations and longstanding partnerships with eMobility, electric vehicle, hybrid electric vehicle, autonomy, and energy storage innovators influence how we exceed rigorous safety and regional environmental requirements, anticipate evolving consumer needs, and solve sustainability regulations of the future.