Tailor-Made EV Battery Insulation Solutions
Materials Expertise and Design Know-How for Superior Battery Electric Vehicle Safety
Battery insulation is crucial for EV safety and enhancing battery performance. High-density batteries needed for long ranges and quick charging inherently risk thermal runaway due to their tight cell packaging.
As battery systems vary widely, we offer tailor-made unique safety concept with engineered components for your most effective and efficient solution.
A comprehensive Thermal Insulation System (TIS) combines:
- High heat-resistant thermal insulation materials
- Intelligent design that meets customer-specific battery safety requirements while being lightweight and space-saving.
Thermal and Electrical Insulation
There are two types of insulation to consider:
- Thermal insulation makes sure that the battery pack, cells, and modules can withstand high temperatures to avoid overheating
- Electrical insulation means that EV battery parts can deal with a defined voltage without causing any failures.
At Oerlikon, our expertise in advanced material development and extensive automotive design experience enables us to develop customized safety components - heat shields, gas guidance systems, and cell separators. All our top-tier components provide superior thermal and electrical insulation.
While our focus is on safety for passengers and vehicle, an efficient battery pack insulation also extends the cell’s lifespan by maintaining ideal operating conditions.
Tailor-Made Insulation Solutions for all Types of Vehicles
Our solutions enable automotive manufacturers to enhance passenger safety in E-Mobility whether:
- Plug-in Hybrid Electric Vehicle (PHEV)
- Battery Electric Vehicle (BEV)
- Fuel Cell Electric Vehicle (FCEV)
What is Thermal Runaway?
Thermal runaway occurs when a battery cell overheats and hot and conductive reaction gases are released explosively through the cell vent. Overheating can be caused by internal or external short circuits (contamination or crash), external heating, overcharging, or cooling system malfunction.
Without protection, this event will trigger thermal runaway in other cells through conductive heat transfer to adjacent cells, through the hot gas stream of a venting cell, or through ignition of the conductive atmosphere by arcing. This chain reaction is known as Thermal Propagation (TP) and can result in severe damage to the battery or vehicle and, in the worst case, fatal consequences for the occupants. The risk of thermal runaway can be minimized by design, but not completely eliminated.
The consequences of thermal runaway for passengers and the vehicle depend on the effectiveness of the safety concept.