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At Ion Lab, we specialise in developing advanced thermal management solutions for energy storage systems. In collaboration with Modul System, we designed and built a battery heater system specifically for extreme cold weather applications.

The Challenge

Lithium-ion batteries struggle to perform efficiently in extreme cold. At temperatures below 0°C, charging can cause irreversible damage to battery cells, significantly reducing their lifespan and effectiveness. For applications in sub-zero environments, it was crucial to develop a system that could warm the battery to a safe operating temperature before charging.

Our Solution

Ion Lab developed a thermal management system that integrates heating elements directly into the battery assembly. These elements gradually warm the cells from -30°C to 0°C, ensuring the battery reaches a safe temperature before charging begins.

This system was carefully designed to provide:

Uniform Heating – The heating elements are strategically placed to distribute heat evenly across all cells, preventing thermal imbalances.
Energy Efficiency – The system uses minimal power while effectively raising the battery temperature to the required level.
Seamless Integration – Designed to work in tandem with the battery management system, the heater automatically activates when needed.

Real-World Testing

To validate its effectiveness, the system underwent rigorous testing in both controlled and real-world environments. In a cold climate chamber, it successfully warmed battery cells from -30°C to 0°C, proving its reliability under extreme conditions. Further testing in real-world applications confirmed its ability to maintain battery performance in freezing temperatures.

This project demonstrates Ion Lab’s expertise in developing practical solutions for challenging environments. By combining innovative engineering with real-world testing, we continue to push the boundaries of energy storage technology, ensuring reliable performance even in the harshest conditions.

At Ion Lab, we focus on creating innovative and cost-effective solutions for battery systems. As part of our research and development efforts, we designed a thermal management system using laser-cut aluminium plates. This approach provides a simple yet highly effective way to regulate battery temperature while keeping manufacturing costs low.

The Challenge

Battery thermal management is critical for ensuring long-term performance and safety. Traditional cooling systems can be complex and expensive to manufacture, particularly for bespoke applications. We needed a solution that was both efficient and easy to produce while maintaining high thermal performance.

Our Solution

We developed a system that utilises laser-cut aluminium plates to manage battery temperatures efficiently. These plates are precision-cut to fit specific applications, allowing us to create customised cooling solutions without the need for costly tooling or machining.

A key challenge in this development was bonding the aluminium plates together. We tested and developed a specialised adhesive system that ensures strong, durable bonds while maintaining excellent thermal conductivity. This allowed us to create lightweight, robust cooling plates that integrate seamlessly into our battery designs.

Benefits of This Approach

Cost-Effective Manufacturing – Laser cutting enables rapid production without the need for expensive moulds or machining.
Customisation – Plates can be easily tailored to specific battery pack designs, providing flexibility for different applications.
Efficient Thermal Management – Aluminium’s high thermal conductivity helps dissipate heat effectively, improving battery performance and longevity.
Lightweight and Durable – The bonded structure ensures a strong yet lightweight cooling solution.

This project showcases Ion Lab’s ability to develop innovative, practical solutions that balance performance, cost, and manufacturability. By leveraging simple yet effective design techniques, we continue to improve battery thermal management for a wide range of applications.

At Ion Lab, we continuously push the boundaries of energy storage technology. As part of our research and development efforts, we have developed a Battery Management System (BMS) with integrated functionality, allowing us to control multiple critical components within an energy storage system.

The Challenge

A standard BMS is primarily responsible for monitoring battery health, balancing cells, and ensuring safe operation. However, many applications require additional control functions, such as managing cooling systems and power distribution. Rather than relying on separate control units, we aimed to develop a BMS with built-in control capabilities, streamlining system integration and reducing hardware complexity.

Our Solution

Our custom-designed Battery Management System incorporates advanced control functions, enabling direct management of:

Contactors – Safely switching high-voltage connections on and off.
Fans – Regulating airflow for cooling to maintain optimal battery temperatures.
Pumps – Controlling liquid cooling systems for enhanced thermal management.
Heating Elements – Activating heaters to keep battery cells at a safe operating temperature in cold environments.

By integrating these functions into the BMS, we have created a more compact, efficient, and cost-effective solution that simplifies system design and improves reliability.

Benefits of Our Integrated BMS

Reduced Complexity – Eliminates the need for separate controllers, reducing wiring and system integration challenges.
Improved Efficiency – Enables real-time coordination between battery management and thermal systems.
Enhanced Safety – Provides precise control over power distribution and cooling, ensuring stable operation in all conditions.

This development showcases Ion Lab’s expertise in designing intelligent, high-performance energy storage solutions. By integrating advanced functionality into our Battery Management System, we provide smarter, more efficient control over battery-powered applications.

At Ion Lab, we are exploring new ways to reuse and repurpose electric vehicle powertrain components. One of our key research areas is the development of a test method to assess the performance of 2nd life motors—electric motors recovered from accident-damaged vehicles.

The Challenge

Electric vehicle motors are built to last, often outliving the vehicles they were originally installed in. When a vehicle is accident-damaged, its motor may still be in good working condition, offering a valuable opportunity for reuse. However, before these motors can be repurposed, they need to be thoroughly tested to determine their performance, reliability, and safety.

Currently, there is no standardised method for evaluating 2nd life motors. The challenge is to develop a testing process that can effectively assess their condition and suitability for reuse in new applications.

Ongoing Research

Ion Lab is in the process of establishing testing methods to measure key performance indicators, including:

Electrical integrity and efficiency.
Mechanical wear and overall condition.
Thermal performance under load.
Suitability for integration into new applications.

Our goal is to create a consistent and reliable assessment process that will allow 2nd life motors to be confidently reused, helping to reduce waste and lower costs.

Looking Ahead

This project is part of our ongoing commitment to sustainability and circular economy principles. By finding ways to repurpose high-value EV components, we aim to contribute to a more resource-efficient future for electric mobility. As our research progresses, we will continue refining our test methods to establish a robust process for assessing and reusing 2nd life powertrain components.