During use and charging, lithium-ion battery cells, packs and modules produce significant amounts of heat, which is why improving safety for electric vehicles is becoming increasingly important. It is possible to mitigate thermal runaway by placing high temperature-resistant materials between the components of the battery.

At Saunders we recommend custom cutting films, fibrous papers, felts, intumescent foams and even composites to prevent thermal runaway.

To ensure safe and efficient batteries, it is necessary to incorporate both dielectric barrier materials and flame barrier films into their production. These components serve as insulators and electrical and thermal barriers. They are lightweight and flame-resistant, making them ideal for a variety of specialized applications.

To prevent electrical discharge between two electrodes we recommend that you use a Polyimide, Teflon, Fiberglass or Kapton tape customized to the specific parts dimensions.

To optimize the functionality of batteries and other electronic vehicle components, it is important to protect them from electromagnetic interference (EMI). The battery management system (BMS)and connecting cables often generate a strong electromagnetic field that can disrupt other electronics. Conductive materials, such as elastomers, foils, seals and adhesive components, can effectively shield against EMI.

We offer converted parts made with various materials, including copper and aluminum foils, as well as conductive PSA. We work with reputable suppliers such as 3M and Saint-Gobain for top-quality EMI/EMC materials.

Saunders’ partnership with top adhesive manufacturers allows us to offer the largest selection of flame-resistant, pressure-sensitive adhesive tapes available. OEMs are increasingly demanding UL-rated components within their packs, and adhesives are no exception. Flame-resistant options include single-sided films, transfer and double-sided tapes.

Sealing battery modules and packs are crucial for proper functionality. These components are usually enclosed between upper and lower housings, with seals in place to safeguard them from air, dust and water exposure. Seals are also responsible for containing any hazardous substances in case of a collision. It is necessary to select gasket and seal materials that can withstand high temperatures and have a UL94 V-0 flame retardancy rating to pass horizontal and/or vertical burn tests.

We recommend using a top-of-the-line raw material manufacturer like Rogers Corporation, 3M and Armacell. Some options from these manufacturers include Rogers BISCO® Silicone, PORON® Urethanes and Saint-Gobain Norseal® Foams, which are the preferred engineering solutions for EV battery gaskets and seals. These materials offer reliable performance in extreme temperatures and are highly resistant to compression sets. Additionally, 3M™ VHB™ double-coated acrylic foam tapes can be utilized for bonding and sealing against moisture and dirt.

Foam compression pads provide predictable and consistent pressure on the cell surface as they go through cell expansion, shock or vibration during the charge/discharge cycles. This is an essential element to prolong the life of a battery. Among the compression pad foam materials Saunders converts are Rogers PORON® polyurethane, Rogers BISCO® silicone and neoprene-based foams.

A wide range of temperatures and conditions make Rogers PORON® and BISCO® ideal for battery cell pads because they offer reliable compression set resistance and stress relaxation performance. Foam pads can also isolate and dampen vehicle-related noise and vibration (NVH/BSR).

While charging or discharging electricity, batteries generate heat that must be mitigated. Excessive heat can negatively impact battery performance and shorten its lifespan. For this reason, it is important to use efficient methods of heat transfer within the battery cells, components, packs and modules.

We offer a range of die-cut thermal management components such as thermal gap pads, graphite components and phase change materials to effectively address these concerns and increase battery longevity.

Furthermore, Saunders converts a variety of flame-resistant materials that meet specific UL temperature-resistant requirements for preventing and suppressing thermal runaway within battery cells and modules. This ensures battery and EV safety components meet the highest standards. Some of our suppliers of thermal management materials include 3M, Rogers, Tesa, Armacell, Laird and more.