Flexible Solutions

4 Insulating Materials for use in EV Batteries

Posted by Katie Sullivan

Aug 27, 2019 9:00:00 AM

Improvements are being made to the lithium-ion batteries used in electric vehicles. Car makers are developing more powerful lithium-ion batteries that have increased range and charge more rapidly. MarianEVBatteryInsulators2Along with these improvements, enhancing safety is becoming increasingly urgent for electric vehicle development.  As mentioned in our previous blog post, 11 Considerations when Selecting Thermal Interface Materials for Electric Vehicle Li-Ion Batteries, Li-ion batteries produce a significant amount of heat while in use and while charging. Along with the use of thermal management materials, placing protective engineered flame retardant insulating materials between the components of the battery cell, module, and pack can offer additional thermal and electrical insulating protection. However, adding such materials can be challenging due to space and weight constraints.

In this post we outline four materials that can enhance the safety of lithium-ion batteries used in electric vehicles.  Some shared characteristics of these four materials are listed below. 

  • ultra-thin
  • light weight
  • electrically and thermally insulating
  • flame retardant
  • can be die-cut and laminated with PSA

Read further for additional detail about each material.


ITW Formex Polypropylene Electrical Insulator Material

Formex™ is a top choice for engineers and designers. It is highly durable with excellent dielectric strength. It is also flame retardant (UL94 V-0) meeting strict safety and environmental requirements.

Formex™ can be die-cut, scored and folded to create a custom dynamic 3D shape. Marian can also laminate Formex™ materials with PSA for ease of placement. 

Download ITW Formex GK Series Data Sheet

Formex Designing for EV


3M™ Flame Barrier Products

3M™ FRB Series Products are thin flexible insulation made of inorganic materials that are flame retardant (UL94 5VA) with high dielectric strength and excellent arc and track resistance. These materials are ultra-thin (<0.245 mm) and lightweight while remaining dimensionally stable. Marian has the capabilities to laminate 3M™ FRB materials with PSA. 

Download 3M™ FRB Series Data Sheet

3M FRB


Kapton® Polyimide Films

FEP-Coated-Polyimide-Film-1280x720

Polyimide Films (also known by the DuPont trade name Kapton®) are widely used in applications where extreme heat and vibration are experienced. Polyimide films are flame resistant (UL94 V-0), maintaining their electrical, chemical and mechanical properties under extremely harsh conditions. 

 

Download Data Sheets -

 


Mylar® Polyester Film

Mylar_Film-1

Polyester Films (also known by the DuPont trade name Mylar®) are also found in many applications where electrical insulation, thermal resistance, and dimensional stability are required. PET films are useful as a dielectric insulator over a relative temperature range. Another product listed above may be more appropriate for higher temperatures, depending on the application within the battery.

 

Download Data Sheet

Polyimide and PET films are often an insulating base of tape products supplied by our partners 3M and tesa. Click here to learn more.


 

Work with Marian

Die-cut-Formex

Marian maintains close partnerships with ITW, 3M, tesa and many other top suppliers of engineered insulator materials. After understanding the thermal, electrical and mechanical requirements of your application, your Marian sales engineer can recommend the most suitable materials. Material samples and prototypes can be provided quickly for testing.  Check out material data sheets.

Marian will determine the appropriate manufacturing techniques to create the custom die-cut components that fit the dimensions and shape of battery application. Marian is also knowledgeable about how the selected materials will accept adhesive, if needed, and how the selected PSA will perform in the conditions of the application. Lamination capabilities include selective zone lamination, combining dissimilar materials, and adding assembly aids such as pull tabs and extended liners.

Contact Marian today to discuss your application or to request a material sample.

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Check out all of the other solutions we offer for the EV Lithium-ion Battery Market.

Topics: Thermal Management, EV, HEV, Material selection, Insulators