Battery Thermal Runaway Protect Mica Sheet Winding Insulation Mica Materials EMI

EPP foam offers numerous advantages as a material for NEV battery insulation and protection. Its unique properties make it an excellent choice for enhancing battery performance, safety, and sustainability.

1. Enhanced Thermal Resistance: EPP foam possesses exceptional thermal resistance, allowing it to effectively dissipate heat generated during battery operation. This capability helps maintain optimal operating temperatures, preventing thermal runaway and ensuring the battery functions efficiently.

2. Superior Insulation Properties: The excellent thermal insulation properties of EPP foam aid in reducing energy consumption and improving battery performance. By minimizing heat transfer, it helps maintain stable temperatures within the battery, optimizing its efficiency.

3. Impact Absorption and Energy Dispersal: EPP foam serves as an ideal material for protecting NEV batteries against impacts. It can absorb and disperse impact energy, reducing the risk of battery damage or rupture in the event of collisions. Its ability to regain its original shape after deformation ensures the structural integrity of the battery and safeguards both occupants and critical electrical components.

4. Lightweight Construction: NEV manufacturers strive to increase driving range and energy efficiency. EPP foam's lightweight nature contributes to achieving these goals by reducing the overall weight of the battery module. This weight reduction enhances vehicle performance and extends the battery's range without compromising safety or durability.

5. Vibration Damping: EPP foam exhibits excellent vibration damping properties, minimizing the effects of external vibrations on the battery pack. By reducing vibration-induced stresses, it ensures stable operation, reduces the risk of internal damage, and extends the battery's service life.

6. Environmental Friendliness: EPP foam is an environmentally friendly material. It is fully recyclable and can be easily processed into various shapes and sizes, minimizing waste generation during production. Choosing EPP foam for NEV batteries aligns with the sustainable ethos of the EV industry, contributing to a greener future.

Overall, EPP foam offers a comprehensive set of benefits for NEV battery insulation, protection, and performance enhancement. Its thermal resistance, impact absorption, lightweight construction, vibration damping, and environmental sustainability make it an ideal choice for the growing electric vehicle market.

Settling on one particular solution for any thermal or electrical junction can be daunting, given the array of choices available.

Polymers for example come in a range of forms to provide different levels of thermal protection for various parts. Silicone and Nomex, for instance, are well-established and widely used throughout EV and HEV components for their thermal, electrical and chemical resistance.

Silicone has strong silicon-oxygen atomic bonds that lend it towards high heat stability and resistance to oxidisation. With operating temperatures typically exceeding 200220 C, silicones are used as insulating sealants for electronic components and as jacket materials for high-voltage cables, for example.

Nomex is similar to Kevlar or Nylon, but with greater thermal and chemical resistance, and has long been used in a range of vehicles (from EVs to racecars) as a thermal and flame barrier, often as a sheet, although it is also available as a fibre. And when manufactured as long, thin sheets, it can be used as a slot insulator between the stator teeth of low-to-medium voltage motors, to reduce the aggregation of heat which might break down the enamelled insulation layer on the copper wires.

Polyester films such as Mylar, Lumirror and Hostphan also provide high thermal and mechanical resistance, and thus have similar versatility to Nomex, being applicable to batteries, motors and other electronic applications. Polyesters have found significant use as insulation for the busbars between battery modules.

As well as films, rubbers and aramids such as these, polyimide foams can maintain their structural integrity between -196 C and +300 C. These have a semi-open cell structure that minimises heat flow as well as sound vibration, making them useful for thermal as well as acoustic insulation.

The physical nature and manufacture of a polyimide foam will vary according to its application. The greater the need for thermal insulation, for example, the more the foam should be ‘densified’ under combined heat and pressure to enhance its thermally resistive properties (and to ruggedise it for harsher environments).