In an trade shifting at tempo, thermal administration, cushioning, and sealing applied sciences are redefining how battery packs are designed, assembled, and guarded.
Responding to the elevated complexity in battery pack design because of the evolution of EVs and hybrids, science-based innovator, 3M, designs and manufactures barrier supplies, cushioning supplies, and sealants.
With a portfolio that features thermal runaway limitations, cushioning foams, sealants, and extra, the worldwide firm is addressing vital points reminiscent of thermal administration, battery pack meeting, value discount, and manufacturing effectivity.
One of the vital urgent considerations in Li-ion battery programs is thermal runaway. To assist deal with this design problem, the corporate provides its 3M Thermal Runaway Barrier 600/700 Sequence, which comprise a compressible, flame-resistant, thermal insulation mat materials. Able to withstanding temperatures as much as 1,200°C, these keep structural integrity even in excessive environments.
Anja Rohmann is a complicated utility engineering specialist. She says, “The mat options non-classified fibers, has good flame resistance, and is designed to assist decelerate warmth switch from one cell to the subsequent. And each collection may be utilized between cells to assist scale back thermal transport in excessive temperatures.”

Rohmann explains {that a} key problem in battery pack meeting is sustaining constant stress inside the battery whereas absorbing mechanical stresses and vibrations. 3M Cell Growth Foam SJCEF is a flame-retardant microcellular polyurethane foam that meets this want. Its self-tacky properties scale back course of steps and meeting time, serving to to streamline operations. Rohmann provides, “It options customizable compression plateau for constant battery stress and is available in a variety of thicknesses, which implies the fabric can accommodate a number of battery designs with out compromising efficiency,” making it very best for each EV and hybrid functions.
Battery enclosures have to be sealed to stop moisture ingress, shield inner parts, and allow future serviceability. 3M Sealant SZ1000 for EV Enclosure Sealing is a two-part, cure-in-place foam sealant designed to fulfill these buyer wants. Providing flame retardancy, glorious getting old sturdiness, and automatic dishing out compatibility, it helps producers to fulfill strict enclosure specs whereas sustaining manufacturing throughput. Rohmann explains that whether or not utilized in EVs or hybrids, the sealant performs a vital function in sustaining long-term battery pack integrity in various environmental situations.
Based on Rohmann, product improvement within the battery sector is something however static. Certainly, OEMs are regularly refining their designs to fulfill shifting efficiency, value, and security targets. She feedback, “The shopper develops and optimizes their battery designs very dynamically in response to continuously altering challenges from the trade. This may typically be very short-term. Our expertise is essential in anticipating sure materials properties or incorporating them upfront.” This speedy iteration cycle presents a problem for materials suppliers, however 3M is ready to stay agile with out sacrificing high quality or reliability.
3M’s strategy to innovation hinges on direct engineer-to-engineer collaboration; that is what the corporate refers to as ‘bench-to-bench’ improvement, upon which Rohmann expands: “Shut collaboration with the OEM is essential for the success of improvement. As soon as key alternatives are recognized, having engineers sit down and discuss via technical challenges permits everybody to grasp the place the ache factors are. Typically these are within the product idea, typically in find out how to combine an modern concept into the manufacturing course of. Via shut collaboration, each events have the chance to be taught concerning the feasibility, improvement potential, and limitations of one another.”

Certainly, it’s right here when an OEM’s challenges develop into 3M’s challenges. “A major concern of OEMs is value discount,” she says, including, “Decreasing the price of battery packs to make electrical automobiles and different functions extra inexpensive is a significant problem.” This, she reveals, entails optimizing manufacturing processes and materials utilization, as nicely balancing efficiency with materials and manufacturing prices.
After which there are challenges related to thermal administration. As vitality density will increase, so does the problem of larger warmth launch. “Effectively managing the warmth generated to deal with security and efficiency is vital,” she displays, stating that superior supplies with excessive thermal stability and low conductivity are at the moment being developed by 3M to deal with this.
Whereas early battery pack designs centered on single-purpose supplies, over time the trade has shifted to multi-purpose supplies, as Rohmann explains, “With larger deal with automobile affordability and industrialization, OEMs are in search of options that not solely meet the appliance objectives, however achieve this in a means that may be simply built-in into their manufacturing processes.” She reveals that OEMs are additionally in search of materials options that assist deal with a number of necessities distinctive to the brand new chemistry and type components which can be in the marketplace.
“Within the case of thermal runaway limitations, because of this the necessities for the chosen supplies nonetheless want to stay extraordinarily excessive by way of thermal stability, however they need to now additionally provide glorious elasticity and prolonged sturdiness.” This nuanced steadiness of properties requires a deep understanding of supplies science and steady suggestions from real-world functions, one thing which 3M is uniquely positioned to perform.
It’s plain that security and environmental laws are additionally shaping product improvement, as Rohmann feedback, “Rules for EVs and thermal occasions are designed to assist deal with security, efficiency, and environmental compliance.”

Right here, environmental mandates, such because the EU Battery Directive and Finish-of-Life Car Directive, are influencing designs by encouraging using supplies that may assist with disassembly and recycling. These components are integrated into the corporate’s R&D plans to take care of future-ready options.
Whereas EV and hybrid battery packs face completely different challenges, reminiscent of vitality density for EVs and ICE integration for hybrids, many options may be shared or complementary between platforms. Advances in battery know-how, thermal administration, and management programs for one sort can typically be tailored for the opposite,” says Rohmann “and enhancements in manufacturing effectivity and value discount methods can profit each full EVs and hybrids.”
This cross-pollination of concepts and applied sciences is what is going to allow strong, versatile options which can be able to addressing the complete spectrum of EV necessities. “By addressing these challenges with modern options and leveraging synergies between full EV and hybrid applied sciences, we will improve the efficiency and competitiveness of each kinds of automobiles,” Rohmann concludes.