Explore the Solutions that Address Your Most Pressing EV Challenges
As we accelerate towards the widespread adoption of electric vehicles (EVs) by 2030, innovations in the world of EVs are receiving a significant boost. Protecting the battery pack, the core of the EV, is essential. Solutions designed to address key challenges such as thermal runaway protection and ensuring the safety and performance of the vehicle are of the utmost importance. Our products frequently prove to be the perfect solution for a wide range of needs, including compression and tolerance pads, thermal runaway safeguards, pack sealing, gasketing, cushioning, electrical insulation, and thermal interface applications.
In our latest interview with Patrick Lynch, Commercial Manager for EV, we delve into the solutions that enable our customers to drive the future of battery-powered vehicles and overcome the most demanding challenges at the cell level, pack level, or within the e-motor.
When you speak with customers, what questions does your team first ask to ensure that you guide them towards the products and solutions they require?
When we engage with customers, we like to understand which area of a battery pack application they are focused on. Understanding whether the customer is seeking solutions at the cell level or the pack module level helps us to guide customers in the direction they need to go and point them towards the solutions they are looking for. In that application area, understanding how the rest of the components fit together is also helpful.
Can you specify what a customer may be seeking if they are focused on the cell level of the battery pack?
At the cell level, customers are mostly looking for compression pads. These are the foam materials that go between each cell and help to control the expansion and contraction (“breathing”) of the cell during charge and discharge cycles, extending the life of the cell. These materials are usually polyurethane foams or silicone foams. We can easily offer these solutions in different thicknesses or densities. We even offer die-cut converted parts for prototype development parts in different shapes, depending on customer needs and specifications.
Sometimes, customers also seek a bonding tape that can attach the compression pad to the cell. We have some thin transfer tapes or double-coated tapes that are ideal for these types of applications. Additionally, we have cases where customers seek materials that can provide thermal runaway protection in between the cells and we have a couple of new products that perform exceptionally well in slowing thermal runaway. Thermal runaway protection is an issue that is a huge topic and a requirement at the cell level, pack level or module level.
Can you specify some of the key applications that customers seek at the pack level?
When looking at the battery pack, we’ve got several different applications. One of the primary applications is what we call pack sealing gaskets. A common application might be for the seal that goes on the battery pack lid, or the cover of the pack. Other areas where gasketing solutions are applied within the pack include vent areas or areas where hoses and wires may come into the pack. Our gasketing materials are typically comprised of polyurethane or silicone and we have solutions for both! Customers also look to put in another layer of material to provide additional thermal runaway protection within the pack itself. Thermal interface materials are also used within the pack. They are silicone materials that can provide heat transfer between cells and a cooling plate or some sort of heat sink. Foam materials are also utilised around the pack itself to help cushion certain areas and keep some sort of vibration cushioning between two different surfaces within the pack.
A cooling plate works to keep the battery cool, correct? Could you explain what other Tape Solutions materials can help with this?
Correct. A cooling plate is similar to what you would consider like a radiator inside a vehicle where they might run fluids through a plate to help keep the battery cool. Thermal interface materials play a key role in keeping this cool. Customers also utilise cushioning pads underneath these cooling plates to help compress or stabilise all the different layers in the battery pack assembly. These cushioning pads help cushion and keep everything together and eliminate the possibility of transferring heat if the thermal interface materials ever get separated from the cooling plate.
There are a lot of electronics that go into a battery pack. The circuit board itself is like the brains of the battery pack. What materials are utilised to protect these elements?
A lot of electronics-specific applications require what is called a V0 rating. This means the materials need very high flame retardancy. These V0 rated solutions are often applied inside the interconnect board or battery disconnect units. Within these types of parts insulation tapes are often utilised. These tapes are also utilised in and around the battery pack. These electrical insulation tapes are made of various materials like polyimide, polyester, PTFE film and glass cloth tapes and they protect the metal areas inside of a pack. A new product we offer is called mica tape and it has been popular due to its very high-temperature resistance as well as good insulation properties.
Saint-Gobain® Tape Solutions offers a wide range of products dedicated to protecting battery packs and ensuring the safety, performance, and longevity of your EV. Furthermore, our bespoke solutions, technical expertise, and global knowledge can help you go the extra mile and shape the future of electric mobility.