The increasing customer demands for Battery Electric Vehicles (BEVs) necessitate new approaches to enhance charging speed and increase maximum range. One potential solution lies in novel cell chemistries, although they require years of development and research to reach market readiness. Another possibility is to increase energy density at the system level.

Battery systems typically comprise a combination of several battery modules, with each module housing numerous cells. This hierarchical structure results in many small gaps that reduce energy density from the cell level to the system level. A “Cell-to-Pack” approach offers a promising means to boost energy density by bypassing the module level, allowing for more efficient space utilization.

To maintain safety in this process, the use of potting materials is an option. These materials envelop the battery cells and have the ability to restrict thermal propagation, thereby improving temperature control, especially during fast-charging processes.

However, the use of potting materials also reduces the cooling of the battery cells, which can have a negative impact on the ability to rapidly charge the battery cells and, consequently, the overall vehicle’s performance. This is because the battery cells heat up more quickly at the same charging currents, reaching the critical temperature window faster.

This study aims to examine the cooling system’s capability to counteract or even prevent this effect. This is crucial for the development of battery systems that ensure both high energy density and safe operating conditions.