Abstract
With the continued adoption of electrified transport and increasing consumer expectations for enhanced range, comfort and safety, the demand for robust and reliable electric vehicle systems is growing. One of the biggest obstacles to providing safe and reliable electric transport is the danger of thermal runaway events. This research addresses the need for a deeper understanding of the thermal behaviour of the cells in an electric vehicle battery array during a thermal runaway event. It also critically assesses the realistic scenarios for managing the heat generated during thermal runaway, and preventing propagation between the cells and through the array. Key approaches explored include the application of liquid cooling channels as well as interstitial materials.
While existing studies have advanced the understanding of thermal runaway, there remained an opportunity to further develop propagation models by aligning them more closely with the real systems they represent. This work presents thermal runaway models consistent with EV architecture, including the array size, cell packing density, the stringent thermal requirements, boundary conditions and optimisation goals. These models bridge the gap between simulation and practical application, by considering the EV specific requirements.
To support model validation a low-power apparatus was designed and manufactured enabling controlled heat transfer studies. As part of this process, a cell analogue was developed that would allow repeated non-destructive testing. This analogue closely replicated the thermophysical properties of a real cell, including the anisotropic thermal conductivity and the volumetric heat capacity.
The models developed showed that the parked and crash scenarios of an EV represent the highest risk states. Moreover, various individual design options and material variations were considered for the role of propagation prevention and thermal management. Additionally, within these models and the designs generated, considerations were made to the constraints of volume and weight, which negatively impact the range and vehicle dynamics that are critical for meeting consumer demands for electric vehicles. Through these simulations the potential use of low conductivity interstitial materials alongside liquid cooling channels to prevent propagation under the most energetic scenarios was uncovered.
To support model validation a low-power apparatus was designed and manufactured enabling controlled heat transfer studies. As part of this process, a cell analogue was developed that would allow repeated non-destructive testing. This analogue closely replicated the thermophysical properties of a real cell, including the anisotropic thermal conductivity and the volumetric heat capacity.
The models developed showed that the parked and crash scenarios of an EV represent the highest risk states. Moreover, various individual design options and material variations were considered for the role of propagation prevention and thermal management. Additionally, within these models and the designs generated, considerations were made to the constraints of volume and weight, which negatively impact the range and vehicle dynamics that are critical for meeting consumer demands for electric vehicles. Through these simulations the potential use of low conductivity interstitial materials alongside liquid cooling channels to prevent propagation under the most energetic scenarios was uncovered. A range of interstitial materials were applied and those with the lowest weight impact were assessed. Through these simulations a range impact of between 0.3 – 2.6 % was calculated for the application of the interstitial materials.
Thesis is embargoed until 31 July 2027.
| Date of Award | Jul 2026 |
|---|---|
| Original language | English |
| Awarding Institution |
|
| Sponsors | Northern Ireland Department for the Economy |
| Supervisor | Peter Nockemann (Supervisor), Stephen Glover (Supervisor) & Oana Istrate (Supervisor) |
Keywords
- Li-ion
- Thermal runaway
- Interstitial materials
- Electric Vehicle
- batteries
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