Elevating EV Battery Performance with Tape Solutions

As the transition to zero-emission vehicles accelerates, many leading automakers are signaling the end of the internal combustion engine era. By 2030, it is projected that one in four-passenger cars will be electric. Despite its rapid growth, the electric vehicle (EV) industry continues to enhance performance, safety, and battery longevity.

This article will explore five ways that Saint-Gobain^® Tape Solutions can assist in delivering more powerful batteries.

Image Credit: Saint-Gobain Tape Solutions

Providing Solutions to Mitigate Risk of Fire Propagation

Automakers are faced with the challenge of maintaining the optimal temperature for battery operation (between 20-40 °C with occasional peaks up to 60 °C). The heat created inside the pack and modules during average use or charging requires management that prevents a thermal runaway event.

Some solutions provide thermal barrier protection to adjacent cells, delaying heat distribution if one cell experiences thermal runaway.

One such solution is the Norseal^® TRP series, specifically designed to prevent adjacent cells from becoming exothermic. These products help mitigate the spread of thermal events between cells through their heat-absorbent, flame-resistant properties. Additionally, the Norseal TRP series provides electrical insulation, preventing arcing within modules.

Making Sound Choices for Material Components Inside the Batteries

Materials used within a battery pack must maintain their properties throughout the vehicle’s lifespan.

For instance, compression pads exert pressure on the front of the pouch or prismatic cells. These pads are designed to function effectively over extended periods, withstanding the rigors of cell compression and expansion. They require spring-like properties to provide a consistent deflection force across a wide range of compression levels and temperatures. This key property is known as compression force deflection (CFD).

Insufficient pressure on a cell allows it to expand uncontrollably in one direction, potentially losing contact with the cooling plate (for thermal management) or disrupting electrical connections. Conversely, excessive pressure can compromise stability and lead to dangerous conditions such as thermal runaway. Saint-Gobain LLP specializes in selecting the appropriate battery pack compression options for specific applications, ensuring sustained functionality and performance.

Another example involves thermal interface materials (TIM), which are used within battery packs to facilitate heat dissipation and enhance energy transfer between the battery components and cooling devices. Saint-Gobain engineers strive to determine the most effective and efficient methods for integrating TIM into battery modules.

Image Credit: Saint-Gobain Tape Solutions

Providing Battery Pack Protection from Mechanical and Environmental Influences

The battery pack, the heart of an electric vehicle, requires protection from environmental elements, mechanical impacts, shocks, and vibrations. Tape Solutions offers unique polyurethane cushioning pads designed to absorb impacts between the pack and the vehicle. These materials boast exceptional rebound properties and a low compression set, helping to dampen mechanical vibrations and maintain flexibility, function, and form throughout the battery’s lifecycle.

Saint-Gobain engineers are eager to discuss products such as foam-in-place gasketing, butyl-coated PVC, silicone foam rubbers, and microcellular foams, ensuring the battery pack is thoroughly sealed and shielded from external conditions.

Product and Assembly Process Optimization

The applications engineering and R&D teams at Saint-Gobain understand the importance of customizing the mechanical properties, tackiness, and hardness of products for each client. If standard customization does not meet the specific needs, they are prepared to explore innovations and co-develop unique tape solutions that address critical or unique performance and technical requirements.

Material properties can be tailored to optimize assembly processes. For example, Norseal compression pads feature customizable characteristics like surface tack and liner options that facilitate automated assembly. Additionally, the properties of the ThermaCool^® products can also be customized to meet specific needs, including:

• Hardness/CFD: Ability to conform to gaps between modules/cell assemblies without exerting excessive pressure on the cells.
• Surface Tack: Helps position the module/cell on the heat sink and minimizes movement during the assembly process.
• Pull Tab Options: To facilitate easier assembly and automate pad placement, the addition of pull tabs can simplify the removal of liners.

Providing Internal Testing Capabilities And Expertise

Customers commonly look for accelerated tests, unique conditions, or application-dependent guidelines that might not be covered by OEM standards or ASTM/other industry testing methods.

Typical test methods include:

Source: Saint-Gobain Tape Solutions

When further testing is required, Saint Gobain’s internal expertise can be used to demonstrate material performance against specific application targets. These tests help identify and eliminate any material shortcomings, ensuring the maintenance of brand integrity.

Accelerate Your EV Projects

The energy transition is accelerating, and the team at Saint-Gobain is enthusiastic about the future of e-mobility. With its expertise and drive, Saint-Gobain is well-equipped to help accelerate EV projects.

Additionally, Saint-Gobain offers an extensive portfolio of products and battery pack protection materials designed to withstand extreme conditions—including temperature, air, smoke, fire, and water—ensuring electric vehicles remain operational for longer.

This information has been sourced, reviewed and adapted from materials provided by Saint-Gobain Tape Solutions.

For more information on this source, please visit Saint-Gobain Tape Solutions.