---
title: Flexible Solutions Blog by Marian | Battery
description: Battery | Read Marian’s blog for engineering insights, material selection tips, application stories, and custom converting solutions across various industries.
image: https://blog.marianinc.com/hubfs/blogcollage-1.png
---

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    - [Thermal Management](https://marianinc.com/materials/thermal-management/)
    - [EMI Shielding & Grounding](https://marianinc.com/materials/emi-shielding/)
    - [Filtering & Venting](https://marianinc.com/materials/filters-venting-fabric/)
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# Flexible Solutions

## [Rogers PORON 40V0: A Thinner UL 94-Rated Solution](https://blog.marianinc.com/blog/poron-40v0)

 Posted by [Ben Hvidston](https://blog.marianinc.com/blog/author/ben-hvidston)

 November 11, 2025 10:00 AM

[![Rogers PORON 40V0: A Thinner UL 94-Rated Solution](https://blog.marianinc.com/hubfs/Rogers-PORON-40V0-blog-featured-image.png)](https://blog.marianinc.com/blog/poron-40v0)

Rogers Corporation’s**[PORON® 40V0 foam](https://marianinc.com/wp-content/uploads/2026/09/17-480-PORON-4701-40V0-Technical-Data-Sheet.pdf)** gives engineers a thinner, softer, and UL 94 compliant solution for gap filling and cushioning.

Unlike standard polyurethane foams, PORON 40V0 combines reliable flame resistance with enhanced compressibility in slimmer grades, making it ideal for space-constrained designs. It also meets strict environmental standards and minimizes contamination risks in critical applications. 

[Read More](https://blog.marianinc.com/blog/poron-40v0)

 Topics: [Thermal Management](https://blog.marianinc.com/blog/topic/thermal-management), [Foams](https://blog.marianinc.com/blog/topic/foams), [Manufacturing](https://blog.marianinc.com/blog/topic/manufacturing), [PORON](https://blog.marianinc.com/blog/topic/poron), [EV](https://blog.marianinc.com/blog/topic/ev), [Battery](https://blog.marianinc.com/blog/topic/battery), [Material selection](https://blog.marianinc.com/blog/topic/material-selection), [Flame Barrier](https://blog.marianinc.com/blog/topic/flame-barrier), [Automotive](https://blog.marianinc.com/blog/topic/automotive), [Sustainable Materials](https://blog.marianinc.com/blog/topic/sustainable-materials), [Rogers Corporation](https://blog.marianinc.com/blog/topic/rogers-corporation), [Data Center](https://blog.marianinc.com/blog/topic/data-center)

## [Why P-THERM® Gap Fillers Are Essential for EV Battery Design](https://blog.marianinc.com/blog/p-therm-gap-fillers)

 Posted by [Ben Hvidston](https://blog.marianinc.com/blog/author/ben-hvidston)

 November 1, 2023 8:45 AM

[![Why P-THERM® Gap Fillers Are Essential for EV Battery Design](https://blog.marianinc.com/hubfs/2023-featured-ptherm-blog-img-1-1.png)](https://blog.marianinc.com/blog/p-therm-gap-fillers)

The rapid advancement of the [electric vehicle (EV)](https://marianinc.com/battery-and-electric-vehicle/) market is no secret, and to keep pace with this progress, OEMs seek cutting-edge [thermal management solutions](https://marianinc.com/materials/thermal-management/) that perform well and come at a reasonable cost.

[Read More](https://blog.marianinc.com/blog/p-therm-gap-fillers)

 Topics: [Thermal Management](https://blog.marianinc.com/blog/topic/thermal-management), [EV](https://blog.marianinc.com/blog/topic/ev), [Battery](https://blog.marianinc.com/blog/topic/battery), [Material selection](https://blog.marianinc.com/blog/topic/material-selection), [TIM](https://blog.marianinc.com/blog/topic/tim), [Thermal Gap Filler Pads](https://blog.marianinc.com/blog/topic/thermal-gap-filler-pads), [Automotive](https://blog.marianinc.com/blog/topic/automotive), [Polymer Science](https://blog.marianinc.com/blog/topic/polymer-science), [Thermal Gap Pad](https://blog.marianinc.com/blog/topic/thermal-gap-pad)

## [Complex Die-Cut EV Battery Components](https://blog.marianinc.com/blog/complex-ev-battery-components)

 Posted by [Brook Girkin](https://blog.marianinc.com/blog/author/brook-girkin)

 July 31, 2023 4:01 PM

[![Complex Die-Cut EV Battery Components](https://blog.marianinc.com/hubfs/multi-layer%20lamination%20cover%20art%20final.png)](https://blog.marianinc.com/blog/complex-ev-battery-components)

##### Combining Intricate Laminations to Create Multifunctional Parts

[Electric vehicles (EVs)](https://marianinc.com/battery-and-electric-vehicle/) continue to experience a sharp growth trajectory, generating process advancements and additional application requirements and needs. Marian has developed improved solutions to meet the industry’s most critical necessities for battery longevity, performance, and passenger safety.

[Read More](https://blog.marianinc.com/blog/complex-ev-battery-components)

 Topics: [Thermal Management](https://blog.marianinc.com/blog/topic/thermal-management), [EV](https://blog.marianinc.com/blog/topic/ev), [Battery](https://blog.marianinc.com/blog/topic/battery), [Die Cutting](https://blog.marianinc.com/blog/topic/die-cutting), [Thermal Pad](https://blog.marianinc.com/blog/topic/thermal-pad), [PSA](https://blog.marianinc.com/blog/topic/psa), [ITW Formex](https://blog.marianinc.com/blog/topic/itw-formex), [Assembly](https://blog.marianinc.com/blog/topic/assembly)

## [4 High Performance Thermal Barrier Materials for EV Battery](https://blog.marianinc.com/blog/thermal-barrier-materials)

 Posted by [Katie Sullivan](https://blog.marianinc.com/blog/author/katie-sullivan)

 April 26, 2021 11:16 AM

[![4 High Performance Thermal Barrier Materials for EV Battery](https://blog.marianinc.com/hubfs/High-temperature-barrier-materials-battery-Marian.jpg)](https://blog.marianinc.com/blog/thermal-barrier-materials)

## Thermal Runaway Propagation Prevention with Thermal Barrier Materials

Hybrid and battery electric vehicles that use lithium-ion cells require these cells maintain specific ambient temperatures. "Thermal runaway" occurs as a result of the rapid rise in temperature within one of the battery cells.

 One of the greatest challenges for battery design engineers is to manage heat. For this reason, batteries are designed with thermal management systems, like thermal gap pads and thermally conductive tapes, that provide different levels of protection, including cell-to-cell, module-to-module, and pack level.

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](https://marianinc.com/materials/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.

[Read More](https://blog.marianinc.com/blog/thermal-barrier-materials)

 Topics: [Thermal Management](https://blog.marianinc.com/blog/topic/thermal-management), [EV](https://blog.marianinc.com/blog/topic/ev), [HEV](https://blog.marianinc.com/blog/topic/hev), [Battery](https://blog.marianinc.com/blog/topic/battery), [Flame Barrier](https://blog.marianinc.com/blog/topic/flame-barrier)

## [4 Insulating Materials for Use in EV Batteries](https://blog.marianinc.com/blog/battery-insulating-materials)

 Posted by [Katie Sullivan](https://blog.marianinc.com/blog/author/katie-sullivan)

 August 27, 2019 9:00 AM

[![4 Insulating Materials for Use in EV Batteries](https://blog.marianinc.com/hubfs/MarianEVBatteryInsulators2.jpg)](https://blog.marianinc.com/blog/battery-insulating-materials)

Improvements are being made to the lithium-ion batteries used in electric vehicles. Auto makers are developing more powerful lithium-ion batteries that have increased range and charge more rapidly. Along with these improvements, enhancing safety has 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](https://blog.marianinc.com/blog/ev-li-ion-battery-tim), Li-ion batteries produce a significant amount of heat while in use and while charging. Along with the use of [thermal management materials](https://marianinc.com/materials/thermal-management/), 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
- lightweight
- electrically and thermally insulating
- flame retardant
- can be die-cut and laminated with PSA

Read further for additional detail about each material.

 

[Read More](https://blog.marianinc.com/blog/battery-insulating-materials)

 Topics: [Thermal Management](https://blog.marianinc.com/blog/topic/thermal-management), [EV](https://blog.marianinc.com/blog/topic/ev), [HEV](https://blog.marianinc.com/blog/topic/hev), [Battery](https://blog.marianinc.com/blog/topic/battery), [Material selection](https://blog.marianinc.com/blog/topic/material-selection), [Insulators](https://blog.marianinc.com/blog/topic/insulators)

## [PORON EVExtend® For Use In EV/HEV Li-ion Pouch Cell Batteries](https://blog.marianinc.com/blog/poron-evextend)

 Posted by [Katie Sullivan](https://blog.marianinc.com/blog/author/katie-sullivan)

 May 29, 2019 1:01 PM

[![PORON EVExtend® For Use In EV/HEV Li-ion Pouch Cell Batteries](https://blog.marianinc.com/hubfs/poron%20ev%20extend%20post.jpg)](https://blog.marianinc.com/blog/poron-evextend)

## Materials for Battery Solutions - PORON EVExtend®

One of our preferred material supplier, [Rogers Corporation](https://www.rogerscorp.com/), has released PORON EVExtend® polyurethane foam material. This material is ideal for battery pads for EV/HEV li-ion pouch cell batteries. The EXExtend 4701-43HBF offers an increased flammability rating of HBF, or HF1 (product dependent). 

[Read More](https://blog.marianinc.com/blog/poron-evextend)

 Topics: [Foams](https://blog.marianinc.com/blog/topic/foams), [PORON](https://blog.marianinc.com/blog/topic/poron), [EV](https://blog.marianinc.com/blog/topic/ev), [HEV](https://blog.marianinc.com/blog/topic/hev), [Battery](https://blog.marianinc.com/blog/topic/battery), [Material selection](https://blog.marianinc.com/blog/topic/material-selection), [Thermal Gap Filler Pads](https://blog.marianinc.com/blog/topic/thermal-gap-filler-pads), [Thermal Gap Pad](https://blog.marianinc.com/blog/topic/thermal-gap-pad)

## [11 Considerations When Selecting TIM for EV Li-ion Battery](https://blog.marianinc.com/blog/ev-li-ion-battery-tim)

 Posted by [Katie Sullivan](https://blog.marianinc.com/blog/author/katie-sullivan)

 March 22, 2019 8:06 AM

[![11 Considerations When Selecting TIM for EV Li-ion Battery](https://blog.marianinc.com/hubfs/EV-Symbol.png)](https://blog.marianinc.com/blog/ev-li-ion-battery-tim)

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. 

[Read More](https://blog.marianinc.com/blog/ev-li-ion-battery-tim)

 Topics: [Thermal Management](https://blog.marianinc.com/blog/topic/thermal-management), [EV](https://blog.marianinc.com/blog/topic/ev), [HEV](https://blog.marianinc.com/blog/topic/hev), [Battery](https://blog.marianinc.com/blog/topic/battery), [Material selection](https://blog.marianinc.com/blog/topic/material-selection)

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- [Kiss-Cut (2)](https://blog.marianinc.com/blog/topic/kiss-cut)
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- [LED Lighting (8)](https://blog.marianinc.com/blog/topic/led-lighting)
- [Manufacturing (24)](https://blog.marianinc.com/blog/topic/manufacturing)
- [Masking (3)](https://blog.marianinc.com/blog/topic/masking)
- [Material selection (34)](https://blog.marianinc.com/blog/topic/material-selection)
- [Material Testing (2)](https://blog.marianinc.com/blog/topic/material-testing)
- [Medical (4)](https://blog.marianinc.com/blog/topic/medical)
- [Medical Device (9)](https://blog.marianinc.com/blog/topic/medical-device)
- [Medical PSA (7)](https://blog.marianinc.com/blog/topic/medical-psa)
- [Peel Strength (1)](https://blog.marianinc.com/blog/topic/peel-strength)
- [Polymer Science (2)](https://blog.marianinc.com/blog/topic/polymer-science)
- [PORON (31)](https://blog.marianinc.com/blog/topic/poron)
- [Prototype (2)](https://blog.marianinc.com/blog/topic/prototype)
- [PSA (36)](https://blog.marianinc.com/blog/topic/psa)
- [PTFE Membrane (3)](https://blog.marianinc.com/blog/topic/ptfe-membrane)
- [Rogers Corporation (21)](https://blog.marianinc.com/blog/topic/rogers-corporation)
- [Rotary (2)](https://blog.marianinc.com/blog/topic/rotary)
- [Seals (18)](https://blog.marianinc.com/blog/topic/seals)
- [Silicone (11)](https://blog.marianinc.com/blog/topic/silicone)
- [Skin-Contact PSA (5)](https://blog.marianinc.com/blog/topic/skin-contact-psa)
- [sputtering (1)](https://blog.marianinc.com/blog/topic/sputtering)
- [Summer Blog Series (5)](https://blog.marianinc.com/blog/topic/summer-blog-series)
- [Surface Energy (3)](https://blog.marianinc.com/blog/topic/surface-energy)
- [Surface Protection (4)](https://blog.marianinc.com/blog/topic/surface-protection)
- [Sustainable Materials (4)](https://blog.marianinc.com/blog/topic/sustainable-materials)
- [Tesa (3)](https://blog.marianinc.com/blog/topic/tesa)
- [Thermal Gap Filler Pads (3)](https://blog.marianinc.com/blog/topic/thermal-gap-filler-pads)
- [Thermal Gap Pad (3)](https://blog.marianinc.com/blog/topic/thermal-gap-pad)
- [Thermal Management (21)](https://blog.marianinc.com/blog/topic/thermal-management)
- [Thermal Pad (5)](https://blog.marianinc.com/blog/topic/thermal-pad)
- [TIM (4)](https://blog.marianinc.com/blog/topic/tim)
- [Tolerance (1)](https://blog.marianinc.com/blog/topic/tolerance)
- [Vent Material (6)](https://blog.marianinc.com/blog/topic/vent-material)
- [Webinar (1)](https://blog.marianinc.com/blog/topic/webinar)
- [Wound Care Device (3)](https://blog.marianinc.com/blog/topic/wound-care-device)

See all

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