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<p>Thermal batteries serve as critical power supply systems for military applications, including missiles and aerospace platforms, where stable operation is required under severe impact, high-temperature, and high-pressure conditions. This study introduces epoxy molding as a reinforcement strategy for the header lid of a thermal battery case, aiming to enhance its impact resistance. The effectiveness of this approach is systematically evaluated using finite element method (FEM) simulations and gas gun impact experiments. The epoxy molding demonstrated superior energy absorption and dissipation capabilities, substantially reducing the maximum depression depth at the center of the header lid. FEM simulations predicted that the addition of a 70&#xa0;mm-diameter, 20&#xa0;mm-high epoxy molding layer decreased the maximum depression depth to 0.78&#xa0;mm, compared to 2.73&#xa0;mm in the unreinforced case, corresponding to a reduction of over 70%. These predictions were validated by high correlation with experimental results obtained from gas gun impact tests. Additionally, the low thermal conductivity of epoxy minimizes heat dissipation, preserving the battery’s thermal efficiency, while its lightweight nature ensures negligible weight penalty, thereby maintaining the structural integrity of the battery system. These findings confirm that epoxy molding is a promising engineering solution for enhancing impact resistance, deformation suppression, mechanical durability, and operational reliability of thermal battery header lids.</p> Graphical Abstract <p></p>

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Enhancing Impact Resistance and Structural Stability of Thermal Battery Cases Using Epoxy Molding: FEM Simulation and Experimental Validation

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月10日

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  • Yeon Taek Choi,
  • Jihye Kwon,
  • Minu Kim,
  • Hyungu Kang,
  • Seung-Ho Kang,
  • Heesook Roh,
  • Sunghak Lee,
  • Hyoung Seop Kim

摘要

Thermal batteries serve as critical power supply systems for military applications, including missiles and aerospace platforms, where stable operation is required under severe impact, high-temperature, and high-pressure conditions. This study introduces epoxy molding as a reinforcement strategy for the header lid of a thermal battery case, aiming to enhance its impact resistance. The effectiveness of this approach is systematically evaluated using finite element method (FEM) simulations and gas gun impact experiments. The epoxy molding demonstrated superior energy absorption and dissipation capabilities, substantially reducing the maximum depression depth at the center of the header lid. FEM simulations predicted that the addition of a 70 mm-diameter, 20 mm-high epoxy molding layer decreased the maximum depression depth to 0.78 mm, compared to 2.73 mm in the unreinforced case, corresponding to a reduction of over 70%. These predictions were validated by high correlation with experimental results obtained from gas gun impact tests. Additionally, the low thermal conductivity of epoxy minimizes heat dissipation, preserving the battery’s thermal efficiency, while its lightweight nature ensures negligible weight penalty, thereby maintaining the structural integrity of the battery system. These findings confirm that epoxy molding is a promising engineering solution for enhancing impact resistance, deformation suppression, mechanical durability, and operational reliability of thermal battery header lids.

Graphical Abstract