Navigating New Horizons in Business

BS Technics is directing its focus toward sustainability, a key pillar alongside the Environmental, Social, and Governance (ESG) framework.

BespokePlanet

In the dynamic realm of electromobility and battery manufacturing, rapid evolution is the norm, necessitating innovative solutions to address the highly diverse battery manufacturing processes. A myriad of factors shape the development and production of new Electric Vehicles (EVs) and their batteries, including battery range, safety, optimal joining technologies, and the imperative to reduce car weight without compromising structural performance.

In this ever-changing landscape, a standardized approach is elusive—each manufacturer sets their unique objectives to minimize cost, material usage, and process steps, all while elevating quality, productivity, and safety. Continuous adjustments and alterations to production processes and materials underscore the constant pursuit of refinement and advancement.

Amidst these multifaceted processes, we firmly assert that thermal management stands as a linchpin, wielding profound influence. The selection of materials related to thermal properties emerges as a critical determinant of success in EV battery production, underpinning reliability and performance effectiveness. Thus, we are eager to present a comprehensive array of selectable material solutions tailored for the EV battery industry.

BSP has diligently concentrated its efforts on
the downstream sector within the global supply chain.

The term "supply chain" encompasses the comprehensive process involved in creating and delivering a product to the end consumer. In the context of EV batteries, the production and usage steps can be broadly categorized into four key stages:

Upstream

Raw materials such as lithium, cobalt, manganese, nickel, and graphite are extracted from mines.

Midstream

Raw materials undergo purification and processing to create cathode and anode active battery materials.
Commodities traders play a role in buying and selling these processed raw materials to firms involved in battery cell production.

Downstream

Battery manufacturers play a crucial role in assembling battery cells into modules and packaging them for sale.
These batteries are then sold to automakers, who integrate the finished batteries into their EVs.
Some automakers, like Ford and Stellantis, have established partnerships with battery manufacturers to produce batteries for their vehicles.

End of Life

When batteries reach the end of their useful life, they can be repurposed, reused, or recycled to minimize environmental impact

In May 1962, at Rice University, U.S. President John F. Kennedy delivered a resolute declaration: "We choose to go to the Moon in this decade and do the other things, not because they are easy, but because they are hard, because that goal will serve to organize and measure the best of our energies and skills, because that challenge is one that we are willing to accept, one we are unwilling to postpone..."

Fast forward over five decades since that pivotal moment, and we find ourselves reflecting on another groundbreaking innovation—the integrated circuit, introduced more than 50 years ago. Since the inception of the International Technology Roadmap for Semiconductors (ITRS) in 1991, it has served as a guiding light for the progress of the semiconductor industry, charting a course in sync with Moore's Law scaling. However, as we stand today, while relentless advancements in design and process technologies continue to propel us towards advanced nodes, the economics and performance promised by Moore's Law are showing signs of reaching a plateau.

In response to this pivotal inflection point, BSP® (BeSpokePlanet) has leveraged top-tier talents within the industry to pioneer ISB®—Induction Selective Bonding. This groundbreaking technology embodies our commitment to advancing all aspects of Heterogeneous Integration, providing superior service and cost-effectiveness to our esteemed customers. ISB®, with its distinctive features, stands at the forefront of this technological revolution.

Thermal management Solution

Battery cells inherently generate heat during charging and discharging cycles, necessitating efficient thermal management to ensure safety and maintain long-term battery capacity. This is achieved by employing Thermal Interface Materials (TIM) between the battery tray and cell modules to mitigate overheating. These TIMs facilitate active thermal management within large battery packs by effectively dissipating the generated heat into appropriate cooling structures.

However, the utilization of conventional thermal interface materials, enriched with specialized fillers, poses challenges due to their elevated weight and cost. These factors have a direct impact on the overall weight, range, cost, and carbon footprint of the electric vehicle.

Moreover, precise considerations regarding tolerances in the fit between the battery compartment and cell modules are crucial. Inadequate application of the TIM can result in insufficient filling and air pockets, while excessive material can lead to squeeze-out and wastage. During the cover assembly, overpressure issues may arise, potentially causing damage to the sensitive cells, thereby affecting battery performance and safety.

Additionally, the high density of the gap filler often leads to barrels being only partially filled, necessitating more frequent barrel changes. Conventional pumps may struggle to empty barrels completely, requiring manual ventilation and purging after each change. This manual intervention leads to increased efforts, decreased productivity, and material waste during the supply process. Addressing these challenges is crucial for advancing thermal management solutions in battery technology.

BSP Special Materials for
EV Battery

PRE-HEATING SOLUTION

PI SOLUTION

BUS BAR PROTECTION

INSULATION SHEET AND FILM

UL94 V0
CTI 0

MICA SOLUTION

Fire Protection “Propagation”

In the unlikely event of EV battery cells igniting, there is a risk that they will burn through the battery cover. For example, the latest safety regulations in China specify that a passenger must have at least five minutes to leave the vehicle in case of a fire emergency. One approach is to cover the battery lid with a layer of a liquid applied fire-resistant material. These are often two-component(2C) materials.

CHALLENGES
The material layer must have a defined thickness on the entire surface of the cover. Gaps and overlaps must be within tight tolerance ranges to avoid issues in downstream production processes. Typical spray applications of materials like epoxy have many disadvantages. Material particles in the air are a health risk. Spray applications also require masking, resulting in waste and factory contamination. It needs high investments to protect workers and equipment. The alternative is a flat stream application. But applying 2C materials with flat stream has been difficult up to now.

The development of safe cells is of utmost importance for a breakthrough in the electrification of transport and stationary storage, because an uncontrollable increase in temperature of the entire system (so-called ‘thermal runaway’) can cause an ignition or even explosion of the battery with simultaneous release of toxic gases. If a single-cell thermal runaway occurs, the next step is to prevent the propagation of the thermal runaway from one cell to the neighbouring cells – known as thermal propagation – or at least extend the time until thermal propagation to five to 10 minutes. This should give the passengers in an electric vehicle enough time to escape or to be rescued by emergency services. The large scale ARCs are well suited for studying thermal propagation