Sponsored by Avery Dennison.
A conformable dielectric tape answer
EV battery pack voltages are growing, leading to larger pack power density and improved car efficiency. With this enhance, nonetheless, comes a larger want for dielectric options that aren’t solely dependable and sturdy, however complement trendy pack design and the wants of producing processes.
The Avery Dennison Volt Robust™ Portfolio of dielectric PSA tapes for EV batteries addresses these wants. The subsequent-generation Volt Robust™ Stretch providing gives producers with a dielectric answer that’s stampable, conformable, resistant to ripping, and accommodates the warmth circulate wants throughout the pack.
Prevention {of electrical} arcing in EV battery packs is crucial
The evolution of EV battery pack voltage and power density has been pivotal in enhancing car efficiency and vary.
At this time’s EVs make the most of battery packs working at 400V or 800+V. This allows sooner charging occasions and extra environment friendly energy supply to the motor. Concurrently, enhancements in power density — the quantity of power saved per unit of mass or quantity — have allowed for lighter, extra compact battery packs that may retailer extra power.
Prevention {of electrical} arcing has all the time been a core security concern in battery pack design. With this progress in pack efficiency, nonetheless, prevention has turn out to be crucial to forestall quick circuits; thermal runaway; or electrical hazards for the driving force, passengers, and repair technicians.
An summary of conventional dielectric safety options
Strong, cost-effective dielectric safety options are thus wanted, and EV battery producers have employed a wide range of strategies. The most typical are dielectric coatings (utilized by spraying or dipping), or pressure-sensitive (PSA) tapes using dielectric movies akin to PET or polyimide.
These coatings and tapes could be utilized to the inner elements of a battery pack to forestall unintended electrical conduction. They guarantee battery packs can function successfully in numerous circumstances, enhancing their efficiency and longevity, and enhancing driver and passenger security.
Dielectric coatings have loved an added benefit over movie tapes because of their skill to be simply utilized to stamped metallic components with advanced geometries. As producers proceed to evolve their designs, conformability has turn out to be an more and more essential requirement for dielectric supplies.
Shortcomings of conventional conformable dielectric options
Dielectric coatings can certainly be efficient electrical insulators in trendy EV batteries, and they’re extremely interesting because of their conformability. Nonetheless, these coatings do have shortcomings that may have an effect on the manufacturing course of and the general effectiveness of the battery pack design.
Higher conformable dielectric options are wanted that permit producers to keep away from these shortcomings. PSA tapes with stampable dielectric movies, designed to be stamped and fashioned with their underlying substrates, are simply such an answer.
Evaluating stampable dielectric tapes towards competing dielectric applied sciences
A brand new kind of PSA tape know-how is now out there that addresses these shortcomings. This tape contains a extremely conformable dielectric movie facestock that’s totally appropriate with metallic stamping processes.
The tape could be utilized to a metallic clean (guide or automated software course of), then stamped together with the clean. The result’s a fashioned metallic half with dielectric safety already utilized. Not like coatings, the PSA tape and its conformable dielectric movie resist injury or cracking within the press.
In testing accomplished on the Avery Dennison Efficiency Tapes laboratory, an ISO-9000 facility, samples of a PSA-based dielectric safety answer had been utilized to aluminum sheet metallic blanks. The samples had been then stamped to check the sturdiness of the tape below numerous pressures typical of commercial metallic stamping. In all instances, the PSA answer withstood utilized pressures, even in excessive situations when ample stress was utilized to crack the aluminum substrate.
Right here’s how this new know-how compares to conventional dielectric options.
There are a bunch of challenges related to dielectric coatings, together with:
- Restricted meeting line flexibility
- Elevated waste and price
- Lack of conformability to advanced components/shapes
- Restricted area in battery pack because of dielectric coating thickness
- Massive bodily tools footprint
- Simply torn or cracked
Fortunately, Stampable dielectric PSA tapes present an alternative choice to the above challenges, by way of the next options:
- Much less labor-intensive course of and sooner meeting line
- Decrease scrap charges and better manufacturing charges
- Stampable tapes mix excessive elongation at break and excessive tear resistance
- Stampable dielectric PSA tape gives considerably extra dielectric energy per unit of thickness in comparison with a typical dielectric coating
- Bodily footprint for tape software is considerably lower than what’s required for coating software
- Very excessive elongation at break mixed with excessive tear resistance.
Introducing Subsequent-Technology Volt Robust™ Stretch | A PSA-based stampable dielectric answer from Avery Dennison
Avery Dennison has developed and launched a PSA-based dielectric safety answer. A part of the corporate’s Volt Robust™ portfolio, this tape is the following era of the Volt Robust™ Stretch PSA dielectric tape (Avery Dennison half quantity FT 0031).
This answer is designed to accommodate a variety of wants whereas addressing key challenges for electrical insulation in battery packs. Importantly, this new tape answer is very appropriate with metallic stamping processes and different metal-forming methods.
Put merely, next-generation Volt Robust™ Stretch could be utilized to a metallic clean, then stamped into a fancy form with out vital threat of the tape cracking, tearing, or sustaining another kind of harm.
Like all PSA tapes, next-generation Volt Robust™ Stretch is straightforward to use and reposition, contains a skinny profile, and is sturdy for the lifetime of the battery.
Purposes
Subsequent-generation Volt Robust™ Stretch can be utilized for bonding and safety in numerous purposes all through a battery pack. It has been more and more used with cooling plates and pack buildings.
- Pack structural elements
- Versatile and inflexible busbar and cell connection programs in EV battery assemblies
- Varied cooling elements, together with chill plates and cooling ribbons
Avery Dennison options for EV battery manufacturing
The Avery Dennison EV Battery portfolio contains numerous practical bonding and safety tapes constructed on a number of PSA applied sciences. These are engineered to make EV batteries safer, extra environment friendly and simpler to assemble.
The portfolio will help producers resolve among the most typical challenges in battery design and building, together with lowering flammability, boosting dielectric energy and design/meeting optimization.
Past bonding
Avery Dennison Efficiency Tapes provides intensive assist past its product portfolio. This contains offering converters and finish customers with entry to testing and collaboration with subject material consultants to develop distinctive options for EV Battery purposes.
Contact Avery Dennison to be taught extra
When you’re an OEM, automotive tier provider or converter consultant trying to higher perceive the potential for PSA tapes in EV batteries, please contact us immediately at dustin.winter@averydennison.com or max.vanraaphorst@averydennison.com.
To be taught extra about Avery Dennison Efficiency Tapes’ options, go to www.tapes.averydennison.com/evbattery.
