Understanding the Benefits of Mica Tape in EV Applications
Did you know that mica materials are often utilised to enhance vehicle safety due to properties such as excellent thermal resistance and strong dielectric properties?
Mica has electrical insulator properties, allowing it to serve as an effective insulator for battery compartments as well as their charging components. It can be combined with pressure-sensitive adhesive tapes to provide excellent adhesion performance to substrates such as stainless steel or aluminium while still maintaining outstanding flame resistance and the ability to help mitigate the severity of battery thermal runaway in EV battery packs.
In this article, we interviewed Patricia Adame, EV Applications Engineer at Saint-Gobain® Tape Solutions to explore one key product, CHR FR1000. We discussed its features, benefits and learned more about how it is utilised and applied.
What is CHR FR1000?
CHR FR1000 is a tape made up of three distinct layers. The first or top layer consists of mica reinforced with glass fibre, the second or middle layer is made of silicone pressure-sensitive adhesive, and the third or bottom layer is a disposable protective liner.
As CHR FR1000 Tape is manufactured on a mica substrate with high-temperature silicone adhesive, it is highly suitable for applications requiring flame mitigation.
What is the purpose of this tape?
The purpose of this tape is to provide both excellent electrical insulation and flame mitigation. A key advantage of this tape is its ability to withstand temperatures of up to 1000°C, making it an excellent solution for aiding in thermal runaway protection.
CHR FR1000 is a durable, thin-gauge solution for improving thermal protection in specific areas such as solid surfaces, corners requiring substrate bending, or design areas with vulnerable holes. In other words, this product has been specifically designed to help reduce the severity of battery thermal runaway in EV battery packs and to meet the requirements of high-performance electrical insulation under normal operating conditions.
How is this tape applied?
When applying this tape to any substrate, design engineers must first understand the tape’s properties and construction to ensure a smooth application.
Before application, it is essential to store the tape in a controlled environment, away from direct heat sources and sunlight, ideally at a room temperature of 22°C. If the tape is stored at higher temperatures, there is an increased likelihood of liner lock, which can affect how easily the liner is removed from the tape.
Next, to achieve a successful bond, the mating surface must be prepared. It should be cleaned of any oils or debris, which can be done using a clean cloth and a 50/50 or 70/30 cleaning solution of isopropyl alcohol and distilled water. Bonding strength is typically achieved within approximately 20 minutes and improves over the following 72 hours.
Finally, during application, operators must avoid contaminating the pressure-sensitive adhesive by refraining from touching the exposed adhesive layer. If contamination occurs, adhesion may fail. To ensure proper adhesion to the mating substrate, the operator should apply the tape either manually or using a soft foam or rubber roller.
Please contact your Saint-Gobain Tape Solutions representative to confirm that the adhesive used on CHR FR1000 is compatible and will create a strong bond with the intended mating surface.
Does Tape Solutions have any peel strength data related to the performance of this tape?
Yes, the Applications Engineering team has developed and collected data on peel strength for aluminium substrates, both at room temperature and after environmental ageing. Upon request, our team will be happy to connect with you to review and discuss the results of this data further.
How should the liner be removed?
The liner should be removed at an angle, with the operator applying some tension. If the operator attempts to separate the tape from the liner without applying tension, there is a risk of breaking the bond between the mica layer and the reinforcement, which could result in scrap material.
What is the protocol for testing these products to ensure they can satisfy challenging customer demands?
Our teams conduct various mechanical and electrical insulation tests to ensure the products meet the demanding conditions and requirements. Upon customer request, we can also test the addition of abrasive particulate options. Our most common testing methods include the 1000°C torch test, 800°C hot plate test, and UL94 test.
Our team is committed to helping provide a wide range of products to assist with the challenging issue of thermal protection in and around the EV battery pack. Undoubtedly, due to its specific properties, CHR FR1000 is a product worth considering when it comes to improving both battery performance and insulation.
With continued research, customer collaboration and co-development, we are dedicated to bringing you products that can meet today’s demanding requirements and provide complete EV battery pack protection. Connect with our teams today to discuss this product or alternative solutions that might best suit your specific needs.