1. | EXECUTIVE SUMMARY |
1.1. | Introduction to thermal management |
1.2. | Material opportunities in and around a battery pack: overview |
1.3. | Analysis of battery cooling methods |
1.4. | Global trends in OEM cooling methodologies adopted |
1.5. | Total GWh of electric vehicles by region |
1.6. | Global trends in OEM cooling methodologies adopted |
1.7. | Immersion fluids - overview analysis |
1.8. | TIM for EV battery packs - forecast by category |
1.9. | Motor design - OEM strategy breakdown |
1.10. | Overview of thermal materials in EV modules |
1.11. | Evolving power electronics cooling technology: air to liquid to microchannel |
2. | INTRODUCTION |
2.1. | Introduction to thermal management |
2.2. | Introduction to battery thermal management |
2.3. | Battery thermal management - hot and cold |
2.4. | Material opportunities in and around a battery pack: overview |
3. | THERMAL MANAGEMENT OF LI-ION BATTERIES IN ELECTRIC VEHICLES |
3.1. | Current Technologies and OEM Strategies |
3.1.1. | Active vs passive Cooling |
3.1.2. | Passive battery cooling methods |
3.1.3. | Active battery cooling methods |
3.1.4. | Air cooling - technology appraisal |
3.1.5. | Liquid cooling - technology appraisal |
3.1.6. | Liquid cooling - geometries |
3.1.7. | Liquid cooling - alternative fluids |
3.1.8. | Liquid cooling - large OEM announcements |
3.1.9. | Refrigerant cooling - technology appraisal |
3.1.10. | Hyundai's timeline to refrigerant cooling |
3.1.11. | Analysis of battery cooling methods |
3.1.12. | Main incentives for liquid cooling |
3.1.13. | Electric vehicles: passenger cars |
3.1.14. | IONITY - a European fast charging network |
3.1.15. | Shifting OEM strategies - liquid cooling |
3.1.16. | Global trends in OEM cooling methodologies adopted |
3.1.17. | Total GWh of electric vehicles by region |
3.1.18. | Global trends in OEM cooling methodologies adopted |
3.1.19. | IDTechEx outlook |
3.1.20. | Is tab cooling a solution? |
3.1.21. | Integration with whole vehicle thermal management |
3.2. | Emerging Technologies, Li-ion Battery Cooling |
3.2.1. | Immersion cooling - introduction |
3.2.2. | Single-phase vs two-phase cooling |
3.2.3. | Immersion cooling fluids - requirements |
3.2.4. | Immersion fluids for electric vehicles |
3.2.5. | Immersion fluids - properties |
3.2.6. | Immersion fluids - costs |
3.2.7. | Immersion fluids - summary |
3.2.8. | Player analysis |
3.2.9. | SWOT Analysis - Immersion cooling for electric vehicles |
3.2.10. | Emerging routes - phase change materials (PCMs) |
3.2.11. | PCMs - overview |
3.2.12. | Operating temperature range of commercially available PCMs |
3.2.13. | Emerging routes - thermoelectric cooling |
3.3. | Heat Spreaders, Cooling Plates and Cylindrical Cell Solutions |
3.3.1. | Heat spreaders or interspersed cooling plates - pouches and prismatic |
3.3.2. | Chevrolet Volt and Dana |
3.3.3. | Advanced cooling plates |
3.3.4. | Advanced cooling plates - roll bond aluminium |
3.3.5. | Active cell-to-cell cooling solutions - cylindrical |
3.3.6. | Printed temperature sensors and heaters |
3.4. | Thermal Interface Materials for Lithium-ion Battery Packs |
3.4.1. | Introduction to Thermal Interface Materials (TIM) |
3.4.2. | Overview of TIM by type |
3.4.3. | Thermal management - pack and module overview |
3.4.4. | Thermal Interface Material (TIM) - pack and module overview |
3.4.5. | Switching to gap fillers rather than pads |
3.4.6. | EV use-case examples (1) |
3.4.7. | Battery pack TIM - Options and market comparison |
3.4.8. | The silicone dilemma for the automotive industry |
3.4.9. | TIM: silicone alternatives |
3.4.10. | TIM: the conductive players |
3.4.11. | Notable acquisitions for TIM players |
3.4.12. | TIM for electric vehicle battery packs - trends |
3.4.13. | TIM for EV battery packs - forecast by category |
3.4.14. | TIM for EV battery packs - forecast by TIM type |
3.4.15. | Insulating cell-to-cell foams |
3.5. | Thermal Runaway Importance, Detection and Prevention |
3.5.1. | Fire protection - introduction |
3.5.2. | Battery fires in S Korea |
3.5.3. | Causes of battery fires |
3.5.4. | Many considerations to safety |
3.5.5. | Causes of failure |
3.5.6. | Stages of thermal runaway |
3.5.7. | Detecting thermal runaway in a battery pack |
3.5.8. | Gas generation / detection |
3.5.9. | Cell chemistry and stability |
3.5.10. | Thermal runaway propagation |
3.5.11. | Regulation change |
3.5.12. | Thermal runaway prevention |
3.5.13. | Thermal runaway prevention - cylindrical cell-to-cell |
3.5.14. | Prevention of battery shorting |
3.6. | Battery Enclosures |
3.6.1. | Lightweighting battery enclosures |
3.6.2. | Latest composite battery enclosures |
3.6.3. | Alternatives to phenolic resins |
3.6.4. | Emerging materials in fire safety solutions |
3.6.5. | Extra reinforcement needed? |
3.6.6. | Are polymers suitable housings? |
3.6.7. | EMI shielding |
3.7. | Thermal Management in Electric Vehicle Charging |
3.7.1. | Importance of electric vehicle charging infrastructure |
3.7.2. | Thermal considerations for fast charging |
3.7.3. | Liquid cooled charging stations |
3.7.4. | Immersion cooled charging stations |
4. | THERMAL MANAGEMENT OF ELECTRIC MOTORS |
4.1. | Electric motor types |
4.2. | Electric motor type - advantages and disadvantages |
4.3. | Cooling electric motors |
4.4. | Current OEM strategies - air cooling |
4.5. | Current OEM strategies - oil cooling |
4.6. | Ricardo's new motor |
4.7. | Current OEM strategies - water-glycol cooling |
4.8. | Recent advancements in liquid cooling |
4.9. | Cooling methods comparison by motor |
4.10. | Motor design - OEM strategy breakdown |
4.11. | Cooling technology - OEM strategies |
4.12. | Electric motor thermal management overview |
4.13. | Emerging technologies - refrigerant cooling |
4.14. | Emerging technologies - immersion cooling |
4.15. | Emerging technologies - phase change materials |
4.16. | Radial flux vs axial flux motors |
4.17. | Axial flux motors - current players |
4.18. | In-wheel motors |
4.19. | DHX ultra high-torque motors |
4.20. | Equipmake spoke geometry PM motor |
4.21. | Diabatix - rapid design of cooling components |
4.22. | Integrated stator housings |
4.23. | Potting & materials |
4.24. | Integration with whole vehicle thermal management |
5. | THERMAL MANAGEMENT IN ELECTRIC VEHICLE POWER ELECTRONICS |
5.1. | Introduction |
5.1.1. | Power electronics in electric vehicles |
5.1.2. | Power switch technology: a generational shift towards SiC and GaN |
5.1.3. | Benchmarking Si vs SiC vs GaN |
5.1.4. | SiC and GaN still have substantial room to improve |
5.1.5. | Where will GaN and SiC win? |
5.2. | Towards Higher Area Power Density and Higher Operating Temperatures |
5.2.1. | Mega trend in power modules: increasing power density |
5.2.2. | Mega trend in power modules: increasing power density |
5.2.3. | Operation temperature increasing |
5.2.4. | Roadmap towards lower thermal resistance |
5.2.5. | Traditional packaging technology |
5.3. | Review of Packaging Approaches in Electric Vehicles |
5.3.1. | Toyota Prius (2004-2010): power module |
5.3.2. | 2008 Lexus power module |
5.3.3. | Toyota Prius (2010-2015): power module |
5.3.4. | Toyota Prius (2016 onwards): power module |
5.3.5. | Chevrolet 2016 Power module (by Delphi) |
5.3.6. | Cadillac 2016 power module (by Hitachi) |
5.3.7. | Hitachi supplies many other vehicle manufacturers |
5.3.8. | Nissan Leaf power module (2012) |
5.3.9. | Honda Accord 2014 Power Module |
5.3.10. | Honda Fit (by Mitsubishi) |
5.3.11. | BWM i3 (by Infineon) |
5.3.12. | Infineon: evolution of HybridPack and beyond |
5.3.13. | Infineon's HybridPack is used by multiple producers (SAIC, Hyundai, etc.) |
5.3.14. | Tesla Model S (discreet IGBT) and Model 3 (SiC module) |
5.4. | Beyond Wire Bonds: Approaches and Techniques to Sustain the Roadmap Towards Higher Temperatures |
5.4.1. | Al wire bond is a common source of failure |
5.4.2. | Al wire bonding remains strong in IGBT modules |
5.4.3. | Al wire bonding also used in SiC modules |
5.4.4. | Technology evolution beyond Al wire bonding |
5.4.5. | Transition towards direct Cu lead bonding |
5.4.6. | Transition towards Cu pin bonding |
5.4.7. | Transition towards Cu wire bonding using Ag sintered buffer plates |
5.5. | Beyond Solder: Materials and Technology to Sustain the Roadmap Towards Higher Temperatures |
5.5.1. | Die and substrate attach are common failure modes in power devices |
5.5.2. | Die attach technology trend |
5.5.3. | The choice of solder technology |
5.5.4. | Why metal sintering? |
5.5.5. | Sintering can be used at multiple levels |
5.5.6. | Transition towards Ag sintering (Tesla 3 with ST SiC modules) |
5.6. | Advanced Substrates: Technologies for High Temperature and Power Levels |
5.6.1. | The choice of ceramic substrate technology |
5.6.2. | AlN: overcoming its mechanical weakness |
5.6.3. | Si3N4: overcoming its mediocre thermal conductivity |
5.6.4. | The approaches to metallisation: DPC, DBC, AMB, AMC, and thick film metallisation |
5.6.5. | Direct plated copper (DPC): pros and cons |
5.6.6. | Double bonded copper (DBC): pros and cons |
5.6.7. | Active metal brazing (AMB): pros and cons |
5.6.8. | Which ceramic substrate-metallisation technology combinations are most reliable? |
5.6.9. | Ceramics: CTE mismatch for ceramics |
5.6.10. | Examples of various substrate choices in EV power modules |
5.7. | Eliminating Thermal Paste: Key Technology Changes to Sustain Roadmap Towards Higher Temperatures |
5.7.1. | Why use TIM in power modules? |
5.7.2. | Which EV inverter modules have TIM? |
5.7.3. | When will the TIM not become the limiting factor? |
5.7.4. | Why the drive to eliminate the TIM? |
5.7.5. | Has TIM been eliminated in any EV inverter modules? |
5.7.6. | Comparison of various thermal greases |
5.7.7. | Thermal grease: other shortcomings |
5.7.8. | Phase change materials (PCM) |
5.7.9. | Thermal resistance of grease and PCMs |
5.8. | Cooling: Technology Changes to Sustain Roadmap Towards Higher Temperatures |
5.8.1. | Evolving air cooling to direct or jet liquid cooling to microchannel cooling |
6. | COMPANY PROFILES |