Designing a battery module or pack requires balancing several competing thermal factors. The most common strategy is to provide just-enough thermal management to achieve the battery pack's fundamental goals. Adding additional thermal management material only adds cost, weight, and volume. Maximum charge/discharge rate – How fast can you charge or discharge the battery without damaging the cells from excessive heat? An EV may have charging requirements as low as 0.5°C, as high. Four primary methods prevent thermal propagation in prismatic and pouch cell packs, and each method has significant consequences for cell cycle lifetime, the ability to fast charge, and driving. In lower-performance battery packs, aluminum has been the primary material, often used for mechanical structure and heat spreading. For higher-performance battery packs, the amount of aluminum needed for safe, efficient operation may result in a pack that is too heavy and bulky. Aluminum is dense and has poor thermal conductivity (200W/mK), but. Spreading is the best way to prevent thermal propagation in pouch and prismatic cell battery packs because it prevents propagation while extending cell cycle lifetime and fast charging while cutting size and weight. Flexible graphite heat spreaders outperform aluminum and can support high-performance, small, lightweight battery packs. NeoGraf Solut.