For decades, the global automotive industry has been using innovative materials from Oerlikon in cutting-edge technologies. With state-of-the-art thermoelectrical insulation systems, designed to protect passengers in the event of a battery fire, Oerlikon is pioneering efforts to make e-mobility safer and more efficient on a global scale.
The demand of electric vehicles is growing: the increasingly powerful batteries enable greater ranges and faster charging times. However, this also intensifies the requirement for solutions that reliably protect passengers and vehicles.
Dangerous chain reaction: Thermal Runaway
The cells of lithium-ion batteries can overheat due to overcharging or a malfunction of the cooling system. This poses the risk of a phenomenon known as Thermal Runaway (TR): individual cells release explosive hot reaction gases, which can trigger a chain reaction called Thermal Propagation (TP). This occurs when undesired heat transfers rapidly to neighboring cells through arcing or hot gas, resulting in severe damage to the battery and potentially leading to a dangerous vehicle fire. In such cases, occupants may have only a few minutes to escape the vehicle.
Customized protection - safe and efficient
The safety components developed by Oerlikon are the most advanced on the market and meet the highest safety standards. They are suitable for various battery architectures and types.
The materials used are extremely heat-resistant (up to 1400 °C) and provide electrical insulation up to 18,000 volts. This minimizes the risk of Thermal Propagation (Zero-TP) and effectively protects both occupants and vehicles. Additionally, these components also optimize the temperature management of the battery, improve cooling, extend the service life of the cells and increase the overall performance of the battery system.
The modular material concept and customizable 3D component design meet all manufacturer specifications, regardless of cell chemistry, format or battery architecture.
Three solutions for safety concepts for battery electric vehicles
HS433 Cell Separator
Ultra-thin and lightweight at 1.4mm with industry leading electrical insulation >32k.
Learn moreSafeVent® HS850/HS950 for Module Covers and Gas Guidance Components
Ultra-thin and lightweight at 0.8mm with superior temperature resistance up to 1200°C.
Learn moreHS800/HS900 Series High Performance Heat Shield
Lightweight and thin insulation material with scalable thickness starting with 1.0mm and superior temperature resistance up to 1400°C.
Learn moreThe first vehicles are already on the road
Oerlikon has begun large-scale production, commissioned by premium car manufacturers, at the Bremen (Germany) site in the first quarter of 2024. The first vehicles equipped with these new solutions are already on the road. In close collaboration with manufacturers in the global automotive industry, Oerlikon is advancing electromobility worldwide. Plans for market entries in North America and Asia, along with partnerships with additional global automotive manufacturers, are underway.
First exclusively mica-free battery protection
Thanks to Oerlikon's unique material expertise the company became the first supplier worldwide to develop a completely mica-free heat shield. In addition, the materials used are non-petroleum based and meet the highest ESG standards due to ethical material sourcing.
Battery protection systems from Oerlikon - for safe, efficient, sustainable and responsible e-mobility.