Flexible Solutions

Complex EV Battery Components: Combining Intricate Laminations to Create Multifunctional Parts

Posted by Brook Girkin

Jul 31, 2023 4:01:59 PM

Electric vehicles (EVs) 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 and passenger safety. Below we examine some of these requirements and the complex, die-cut EV components Marian manufactures to overcome common challenges related to the battery.

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Topics: Thermal Management, Pressure Sensitive Adhesive, EV, battery, Die-Cutting, thermal pad, Formex, assembly

4 High Performance Thermal Barrier Materials for EV Battery

Posted by Katie Sullivan

Apr 26, 2021 11:16:02 AM

Thermal Runaway Propagation Prevention with Thermal Barrier Materials

Hybrid and battery electric vehicles that use lithium-ion cells require that these cells are maintained at 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 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. 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.

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Topics: Thermal Management, EV, HEV, battery, flame barrier

The Best Thermal Gap Pad for Your Design

Posted by Katie Sullivan

Jul 29, 2020 9:30:00 AM

Thermal gap pads are utilized in electronic devices within the interface, or gap, between a heat generating component and a heat sink. The heat sink or cooling plate is designed to conduct heat away from the heat generating component to keep it cool and running safely. According to Parker Chomerics Thermal Management Engineering Handbook, the typical contact area between most semiconductors and heat sinks can be made up of 90% air voids! We also know that air is about 200 times less conductive than a 5 W/mK  thermal interface pad. This is where the thermal gap pad comes in.

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.

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Topics: Thermal Management, thermal pad, thermal interface material

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. 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
  • lightweight
  • electrically and thermally insulating
  • flame retardant
  • can be die-cut and laminated with PSA

Read further for additional detail about each material.

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

11 Considerations When Selecting Thermal Interface Materials for Electric Vehicle Li-ion Battery

Posted by Katie Sullivan

Mar 22, 2019 8:06:17 AM

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. 

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

Thermal Resistivity and Thermal Conductivity of Silicone Foam

Posted by Katie Sullivan

Jan 27, 2017 10:13:34 AM

Video Demo: Thermal Resistivity and Conductivity of Silicone Foam

Thermal resistivity and thermal conductivity can be two very important physical features of foam materials for certain applications. Most devices containing electronic components must be designed to deal with heat in one way or another. Electronic circuitry operates most reliably at lower temperatures.  High operating temperatures decrease the service life of the device or module. It is critical for designs to either conduct or isolate heat away from delicate components to ensure ideal operating temperatures.

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Topics: Thermal Management, Foams, BISCO Silicone

What You Need to Know about the TR Series

Posted by Katie Sullivan

Jun 22, 2016 11:01:30 AM

Nitto TR Thermally Conductive Adhesive Tape Series

\Nitto’s TR series is a must-have for thermal and electronic applications. The TR series features a selection of double-coated tapes including TR-5912F and TR-5925F. These tapes exhibit powerful adhesion and thermal conductivity which accounts for their strength and reliability. Nitto recommends replacing the use of a screw-in an LED or other thermal applications with these thermally conductive adhesives for the best performance. Using the tape method offers superior thermal conductivity performance, and can extend the life of your LED, compared to using the screw method. 

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Topics: Thermal Management, Pressure Sensitive Adhesive

Thermal Management in LED Light Assemblies

Posted by Katie Sullivan

Jan 11, 2016 10:30:00 AM

Thermally Conductive Materials in LED Assemblies

Although LEDs are considerably more efficient than traditional lighting forms, they do still produce heat. This heat can have an adverse effect on the LED and therefore must be managed to ensure the true benefits of this technology are realized. If excessive junction temperatures are reached, particularly above the maximum operating temperature of the LED (~120-150˚C), a non-recoverable effect could occur, leading to complete failure. Operating temperature is directly related to the lifetime of the LED; the higher the temperature, the shorter the LED life.

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Topics: Thermal Management, LED Lighting

THIN HEAT SPREADERS: Thermal Interface Materials

Posted by Katie Sullivan

Sep 8, 2015 2:00:00 PM

Heat Spreaders

As summer comes to an end, we bring you our final post in our Hot Summer Blog Series exploring Thermal Interface Materials. In this post, we briefly look at heat spreaders.A heat spreader is a heat exchanger that moves heat between a heat source and a secondary heat exchanger whose surface area and geometry are more favorable than the source. Heat spreaders conduct heat in the x,y, and z axes which spreads the heat to a larger surface area for efficient and effective heat dissipation. This heat dissipation keeps devices running at a safe operating temperature. 

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Topics: Thermal Management, 2015 Summer Blog Series: Thermal Management

What Are Thermally Conductive Tapes?

Posted by Katie Sullivan

Jul 24, 2015 10:03:00 AM


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Topics: Thermal Management, 2015 Summer Blog Series: Thermal Management