Flexible Solutions

Sensors, controllers and other electronic elements are being integrated into devices across virtually every industry. Many of these products are made for use in conditions where they may be exposed to extreme temperatures, rain, wind, dust, and moisture. (See application story about "smart" shipping pallets linked at the bottom of this post.) Designing such products requires that the container or enclosure holding the electronic components be completely sealed. Exposure to harsh elements could cause a product failure. 

Among numerous assembly options, automated assembly is often the method of choice for many of our customers. Automated placement is used for projects with very high volumes where precise placement is critical. Automated assembly can also significantly increase assembly speed and efficiency.

Marian designs and manufactures custom components to fit seamlessly into our customers’ automated assembly process. We can modify many different aspects of the final part and packaging from liner type, part spacing and orientation, and quantity of parts per roll.  

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. Along 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.

Prototypes are typically produced in relatively small quantities and used by our customers to verify design, evaluate material choices, and build prototypes of their assembly.

When masking an area with precision and over-masking is unacceptable, custom die-cut masks prove to be the best solution. This video shows a direct comparison of the masking process with strips/knife versus masking with a die-cut part with a split liner. You'll see this demonstration proves that masking with a custom die-cut is easier, faster, more accurate, and safer. 

Our valued material supplier, Rogers Corporation, has released PORON® EVExtend 4701-43RL polyurethane foam material. This is an ideal battery pad material for EV/HEV li-ion pouch cell batteries.

Currently, lithium-ion (li-ion) batteries are the most common type of battery used to power electric vehicles. Today's market is demanding that batteries charge faster and last longer. Because li-ion batteries produce significant heat when in use and charging, thermal management is critical.  Excessive heat can cause irreparable damage to the battery. 

Technological advances in properties of soft, flexible foam and elastomeric materials have continued to advance. These thick, soft, flexible foams and elastomers are ideal materials for sealing, gasketing and cushioning across many industries and applications. They compress, form to irregular surfaces, bend, and flex within an application without damage or de-lamination, but from the perspective of the die cutter, may also introduce challenges when trying to achieve the tight dimensional tolerances common in metal and plastic-molded parts.

We have published a new success story!  In this story, the customer required a static seal for a navigation module that would be contained and used on the exterior of a recreational vehicle.  The exterior navigation/infotainment module would be exposed to outdoor elements including extreme temperature swings, rain, wind and dust.  The gasket was required to perform as designed for the life expectancy of the class A RV.  This can be more than 10 years!  

Ever wonder why hospitals, doctor’s offices, and other healthcare providers don’t just use duct tape for bandages, wound care, and device fixation? Well, there are many reasons, but first try sticking it to skin and peeling it off. The main reason is simple: duct tape does not use a medical grade pressure sensitive adhesive.

Medical adhesives must be skin-friendly, non-migratory, with a variable degree of initial tack and peel adhesion. Ease of removal, breathability and durability also differentiate medical adhesives from other types of tapes.