Flexible Solutions

Thermal Runaway Propagation Prevention with Thermal Barrier Materials

Marian provides custom flexible die cut solutions that are incorporated into battery design at the cell, module and pack level to aid with thermal management. These die-cut parts are made with high temperature resistant materials (also known as flame barrier materials) that are designed to offer thermal insulation to delay the onset of thermal runaway.

The majority of the die-cut parts manufactured by Marian include a Pressure Sensitive Adhesive Tape (PSA). PSA tape is thin flexible material coated with a thin layer of adhesive, making one or both sides sticky. By producing billions of adhesive-backed parts each year, it’s safe to say Marian has a lot of experience with this sticky stuff!

PSA tapes can come in various constructions, which offer different functionalities based on your application. There are double-coated tapes, single-coated tapes, and adhesive transfer tapes. Check out our blog post, Pressure Sensitive Adhesive Tape Constructions, to learn more about different tape constructions.

The first step is choosing the best PSA type and construction for your application (by the way, we can help with this! Download our ebook: 4 Questions to Ask Yourself when Selecting a PSA). An equally important step when utilizing a PSA in the assembly of your product, is the proper storage and proper application of the PSA. Missteps when storing and applying your PSA can lead to product failure.

One of our top material suppliers, 3M, recently announced the release of their next generation of medical silicone adhesives, 3M Hi-Tack Silicone Adhesive Tapes. 3M 2480 is the first product to launch in this new portfolio. It is a single coated medical nonwoven tape with hi-tack silicone adhesive on a liner. The benefits of this exciting new material include:

• Longer wear-times (up to 4 days)
• Supports heavier devices
• Offers more secure adhesion
• Repositionable

Read the full press release from 3M here.

When designing a wearable device that will be attached to the human body, selecting the most appropriate stick-to-skin adhesive is a very important part of the design process, and Marian can help. If you take two things away from this article, they should be the following:

1. Think about material selection early in the wearable device design process.

2. Involve your material converter early in the wearable device design process.

Material converters, like Marian, can be an invaluable resource as you begin to make decisions about your design, including choosing the stick-to-skin adhesive materials.

In the 1960s, Dupont™ developed the versatile and high-performing Kapton® Polyimide Film. Since its introduction, designers have relied on Kapton® film because of its ability to maintain its electrical, thermal, chemical and mechanical properties at extreme temperatures. Kapton® films have been used in many advanced markets including, electronic devices, electric vehicle battery, aerospace systems, power transformers, and more.

Pull-tabs, extended liners and split liners are assembly aids. They make the process of removing the liner from a die-cut adhesive part much easier. When you work with Marian, we keep your manufacturing and assembly process in mind as we develop the solution. Our goal is to make things easier for you, saving you labor and time spent during assembly,  placement, or manufacturing. Once we understand how our part will be assembled into your product, we can often offer a variety of solutions. These solutions can include (but are not limited to):

• Part orientation / spacing on the liner
• Final packaging:
  • Kiss-cut to a liner and wound onto a roll
  • Singulated parts
  • Kiss-cut to sheets
  • Perforated liner
• Modifications to the carrier liner for fixturing
• Pull-tabs, extended liners, split liners

In this blog post, we are going to focus on pull-tabs, extended liners, and split liners.

Silicone rubber materials and some plastic films have chemically inert and non-porous surfaces, which equates to low surface energy. This means they have a weak molecular bonding force making it difficult to create a bond with many pressure sensitive adhesives.

Thermal gap pads are made of soft polymer that flows into the air gaps in the interface to aid in the more efficient and effective conduction of heat.

 Point-of-care and rapid diagnostic testing are increasingly important in the areas of disease detection, treatment monitoring, and preventative care. This market is particularly important as the world faces the COVID-19 pandemic. It is imperative that components of these devices and test kits are reliable and of the highest quality.

Per the Rogers Corporation Website, Rogers “BISCO HT-800 Medium Cellular Silicone offers the lightness of foam with the enhanced sealing capabilities of sponge rubber.” In this post, we are going to dive a little deeper into this excellent material.