D. Jimenez-Rivera, P. Quintero-Aguilo
University of Puerto Rico at Mayaguez,
United States
Keywords: AlN, EV battery, thermal stresses, finite element analysis
Summary:
The proportional development and similarity between semiconductor technologies and electric vehicle battery systems keeps growing in complexity, with better operation performance and smaller footprint. Although these technologies are improving their operation performance, their components are subject to higher thermo-mechanical strains, affecting device longevity and increasing the chance of failure over time. The root cause of these failures could be attributed to different reasons such as user operation, difference of material interfaces, extreme environments, and heat generation; out of these phenomena, heat generation and material interface discrepancy have been the most prominent in the history of high-power electronics. Most noticeably, the recent development and inclusion of Lithium-Ion batteries for electric vehicles has taken over the EV industry, with most EV manufacturers shifting towards the application and usage of them (Lithium-Ion Battery). In 2024, Kia Corporation made the decision to recall over two-thousand units of their 2022 Kia Niro EV, due to a case of overheating on the charging port causing battery failures and shutting down during operation. Situations like these can have a negative effect on the safety of drivers and reliability of vehicles, creating a serious concern to be tackled. By using materials or technologies developed for semiconductor packages, the thermos-mechanical challenges of EV batteries could be addressed. Aluminum Nitride has emerged as a promising ceramic material in thermos-electric applications, due to its high thermal conductivity (285 W/mK), low thermal expansion coefficient (4.5 10-6/°C), and electric insulation properties. These characteristics make AlN an excellent contender for thermal management applications in battery cells and semiconductor packages, by preventing thermal runaway in these systems. To optimize and understand the benefits and behavior of AlN in BTMS, simulation techniques are applied to different geometries. Ansys, a Finite Elements Analysis tool, will be employed to model the heat transfer and generation of the designed battery packs, providing a deeper understanding of the temperature distributions and hotspots. By developing separate 3D model simulations with different operating conditions, the behavior of the systems will be analyzed more efficiently. Recent studies have shown the effectiveness of AlN in different thermal management applications. For instance, AlN has been used as a filler in composite material matrices to enhance the thermal conductivity of battery modules. Additionally, AlN coatings have been applied to battery components to improve heat dissipation and maintain adequate operating temperatures (45°C-60°C). These developments highlight the potential of AlN to enhance thermal management in EVs, contributing to safer and more efficient battery modules. This project aims to explore the role of aluminum nitride in battery thermal management systems for prismatic battery cells, examining its properties, applications, and benefits using simulation techniques and geometries; as well as the interaction with phase change materials, to provide better thermal capturing. By making use of the unique characteristics of AlN, we can develop more effective BTMS solutions that meet the demanding requirements of modern electric vehicles.