The rapid advancement of the electric vehicle (EV) market is no secret, and to keep pace with this progress, OEMs seek cutting-edge thermal management solutions that perform well and come at a reasonable cost.
Among essential materials used for heat management in EV batteries, thermal gap pads (aka thermal gap fillers) play a crucial role. Marian collaborates with suppliers like Polymer Science, whose partnership allows for development of high-quality thermal gap pad materials along with various other essential materials for managing heat in EVs.
We sat down with John Biddle, Vice President of Product Development at Polymer Science for a Q&A session where we discussed their contributions to the production of thermal management materials and the benefits they provide.
Q&A With John Biddle - Polymer Science, VP Product Development
Q: Why are thermal gap fillers essential to EV and battery applications and what solutions do they provide?
A: Thermal gap fillers are designed to keep components at optimal operating temperatures. Gap filler pads are easy to manage and make no mess when applied. They can also be customized to different shapes & sizes and are repositionable during assembly.
Q: How do gap fillers reduce the risk of thermal runaway and make EVs safer?
A: Gap pads effectively transfer heat from cells to the cooling plate. They also play a crucial role in compressing the cluster of cells and module housing, effectively damping vibrations caused by external forces and ensuring safety of the battery.
Q: How can a P-THERM® Gap Filler material contribute to the weight reduction of an EV and enhance its efficiency?
A: Studies have shown that for every 7 kgs of weight reduction in an EV, an additional mile of range can be achieved, emphasizing the importance of weight reduction in all aspects of EV design. This plays a vital role in enhancing overall technology and efficiency of electric vehicles.
Polymer Science provides durable solid gap fillers that can be precisely die-cut by expert converters like Marian, allowing for perfect placement of gap fillers for OEMs and ensuring optimal performance and efficiency.
Q: What are some successful examples of P-THERM® Gap Fillers in battery applications?
A: I'd like to highlight two thermal gap fillers: PS-1543 and PS-2643. These materials have been used in applications with Marian and are highly successful in the market.
- In a recent application, Marian's engineering team incorporated PS-1543 into a thermal multi-layer lamination for the customer's battery application. This innovative solution included an additional layer of fortified polyimide reinforcement added by Marian, further enhancing the performance and durability of the battery.
- Our newly released PS-2643 showcases state-of-the-art advancements within the latest product line. This lower-cost 3 W/m K pad not only delivers outstanding performance, but it also offers a remarkable cost reduction for battery OEMs.
Both gap filler pads have proven effectiveness when applied between battery cooling plates and cells.
Q: What distinguishes Polymer Science from competitors?
A: At Polymer Science, we differentiate ourselves with our innovative five-step methodology. This enables development of tailor-made material solutions that bring customer projects from concept to market quickly and efficiently.
We also prioritize customer satisfaction by offering custom roll-widths that minimize waste, maximizing yield for our customers. With our solid gap fillers and other materials produced in roll format, Polymer Science facilitates rapid and high-volume converting processes. Located in the heart of the midwestern United States, our global headquarters ensures competitive pricing for North American battery manufacturers.
Q: What are the essential characteristics of Polymer Science's P-THERM® Gap Filler product line?
A: P-THERM® Gap Fillers are available in varying constructions, including silicone and non-silicone versions that are supplied on rolls or sheets.
There are also a number of other important considerations when choosing the appropriate thermal management material for your application. Take a look at some of the other notable characteristics of the P-THERM family of materials below.
- Thermal conductivities: range from 1 - 5 W/m K
- Typical thicknesses: range from 0.10mm - 5.0mm
- Durometer range (Shore 00): 5 - 80 based on product type
- Various colors available
- UL V-0 rated
- RoHS and HF compliant
- Good surface wetting
- Conformable
Q: What makes Marian and ideal converter for EV manufacturers looking to incorporate Polymer Science's P-THERM® Gap Fillers into battery applications?
A: With over two decades of experience in product development at Polymer Science, I've had the privilege of collaborating with Marian. Marian distinguishes themselves by offering unparalleled support to OEM and tier customers in the industry. They go above and beyond to deliver exceptional service and quality engineered parts through various means like:
- Offering guidance to customers in material selection, including access to top global manufacturers, such as our team at Polymer Science.
- Providing rapid prototyping services to actively involve customers in the material selection process while also testing the design of their solution.
- Engaging in conversations with experienced Process Engineers to facilitate design for manufacturing
- Exploring automation possibilities
- Demonstrating their expertise in intricate converting techniques for large-scale manufacturing
Q: What other material solutions does Polymer Science offer to contribute to the advancement of EVs?
A: In addition to P-THERM® Gap Fillers and two-part dispensable thermal gap fillers, we also offer a wide range of innovative materials that significantly enhance performance and efficiency of EVs including:
- Cutting-edge phase change materials that enable efficient heat transfer and temperature regulation
- Advanced heat spreaders that efficiently dissipate heat and maintain optimal operating temperatures.
- Innovative electronic control interfaces that enhance the functionality and reliability of EV systems
- Reliable adhesives that ensure secure bonding and sealing of components
We also provide top-notch EMI shielding and grounding materials through our P-SHIELD® product line, which offers a wide array of options including fabric tapes, film tapes, foil tapes, foam tapes, and adhesives.
"We are committed to providing solutions that improve the overall performance, durability, and sustainability of evs."
Work with Marian for Your EV Thermal Management Applications
Marian maintains a strong working relationship with the teams at Polymer Science along with several other renowned global materials suppliers. These partnerships greatly enhance our ability to provide exceptional die-cut thermal management solutions to our customers who are leaders in EV battery manufacturing. Reach out to us today and discover the capabilities of Marian's custom-engineered die-cut solutions.
Experience the full range of EV battery components we manufacture in the video above.
Marian Brochure: Die-Cut Solutions for Transportation Electrification
Marian specializes in manufacturing custom die-cut components for various areas of the battery from the individual cell to the module and pack.
eBook: How to Select the Right Thermal Interface Material
Our free eBook explores the essential characteristics of various thermal interface material (TIM) families and dives into the considerations for selecting the right thermal interface material.
