Thermal Management Applications
Advanced thermal management solutions using high-performance materials
Advanced Thermal runaway barriers
Delay and prevent propagation from a thermal runaway event
Thermal runaway is a high-consequence event where internal cell temperatures can spike to above 1,000°C. Whilst thermal runaway is rare in Electric Vehicle (EV) and BESS platforms, it remains a critical safety challenge for pack development.
Instantly and effectively managing the extreme thermal energy from a thermal runaway event, prevents it from propagating to adjacent cells, which is the difference between a single cell failure and the entire battery pack being compromised.
Our OEM-approved thermal cell barriers, known as Anti-Thermal Propagation (ATP) pads, are a leading solution to address this persistent industry challenge. Developed at our IATF-certified facility in collaboration with leading automotive OEMs, our solution is used across electric vehicle ranges, providing a superior thermal propagation delay with results from over 20 minutes to complete prevention.
Anti-Thermal Propagation (ATP) Pads
Surpass safety regulations, extend cell life & optimise performance
Engineered for prismatic, pouch, cylindrical and solid-state cells, our advanced thermal cell barriers prevent or delay thermal propagation from neighbouring cells following a thermal runaway event
Surpass safety Regulations
The updated GB38031-2025 regulation, enforced in China from
1st July 2026, increases required thermal containment time from 5 minutes to 2 hours. Meeting this strict mandate can be achieved with advanced thermal cell barriers engineered for your specific battery pack that address all factors needed to effectively isolate thermal runaway.
Enhance cell performance
Our ATP Pads incorporate innovative design features to optimise both the performance and lifespan of the cell, while maximising pack safety. Integrated spacers can provide optimal spacing, allowing our ATP pads to provide consistent thermal insulation and effective cell wall pressure. Whilst adhesive layers increase battery pack rigidity, enhancing safety and performance.
Full Customisation
Tecman’s ATP pads are engineered entirely around your battery pack and can be produced in various sizes, thicknesses, and multi-material combinations—with or without custom spacer frames.
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Pouch Cell Solutions
Combining cutting-edge, lightweight insulation materials with specialised encapsulation films. These ultra-thin barriers prevent cell-to-cell thermal propagation while providing critical cell compression.
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Prismatic Cell Solutions
Framed ATP Pads combine lightweight material and cell-spacer technology enabling ground-breaking anti-thermal propagation solutions that prevent thermal propagation from a thermal runaway event.
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Cyclindrical Cell Solutions
Lightweight, high-performance ATP solutions provide excellent passive protection and compression to delay or prevent thermal propagation between cylindrical cells from a thermal runaway event.
Contact Us Today
to Discuss Our Thermal Runaway Barrier Solutions
Our ATP Pads are customised for your specific battery pack requirements and manufactured using an industry-leading all-in-one process for efficient, high-volume manufacturing.
Tecman’s ATP Pads are far beyond the concept stage, being in full serial production and deployed in vehicles around the globe. This proven technology enables OEMs to accelerate the path to safer, higher-performing EV batteries, while providing:
- Superior Safety: Delay cell-to-cell thermal propagation by over 20 minutes.
- Improve Cell Longevity and Performance: Control cell compression during service and charging
- Bespoke Solution: Engineered to your battery pack and exact requirements to deliver optimal safety and performance improvements.
- Unrivalled Scalability: High-speed, all-in-one manufacturing systems capable of producing up to 120 parts per minute.
The Tecman team are on hand to demonstrate how our advanced thermal cell barrier technology can help you achieve improved battery pack safety and optimise performance.
All-in-One ATP Pad Manufacturing Systems
Making Cost-Efficient ATP Pads a Reality for EV & BESS platforms
Tecman’s cost-effective, all-in-one manufacturing system for ATP technology greatly improves the efficiency and sustainability of
anti-thermal propagation technology for battery production.
Low-Cost Regional Manufacturing
Our state-of-the-art manufacturing system has a compact footprint, enabling it to integrate seamlessly into existing clean production facilities or dedicated spaces close to battery assembly lines, maximising space efficiency and reducing facility costs.
Enhanced quality control
Automation within the system not only reduces labour costs but also improves quality control through in-line closed-loop adjustments and 100% part inspection, ensuring consistent, reliable production. The flexibility to handle different materials and part sizes allows OEMs to accommodate evolving battery technologies and specifications without compromising efficiency or quality.
High-Volume Continuous Operation
The all-in-one manufacturing system eliminates the need for third-party pre-conversion, which reduces operational costs, simplifies the supply chain, and enhances overall production efficiency. The ability to produce up to 120 parts per minute, with a total capacity of up to 36 million parts per year, ensures high output, continuous operation and minimises downtime.
Sustainability benefits
Tecman’s thermal cell barriers are engineered with sustainability in mind by reducing material waste and energy consumption in the production process. The ability to locate the compact manufacturing system in close proximity to battery assembly lines also minimises logistical costs and transport emissions, creating a more efficient and sustainable supply chain.
Improved Profitability
By improving efficiency, reducing production costs, and ensuring high-quality output, our ATP technology enhances profitability for OEMs, helping achieve financial goals while maintaining industry-leading standards.
Strategic Partnership
Tecman build lasting partnerships through collaboration, transparency, and reliability, offering tailored solutions to meet financial objectives and ensure supply chain resilience.
Advanced Thermal Runaway Barrier Case Study
Delaying thermal propagation by over 20 mins in an EV battery pack
challenge
Develop a single manufacturing process for an anti-thermal propagation solution to optimise space between cells and control expansion and contraction to improve cell life and performance.
solution
A highly efficient compact manufacturing process suitable for integrating into existing production facilities, manufacturing Framed ATP Pads in one continuous production run without the requirement of a 3rd party converter.
outcome
Cost-efficient manufacture of 36 million OEM approved Framed ATP Pads per year at close proximity to battery assembly plant or at customers' own facility. Superior anti-thermal propagation using advanced technology improves safety and increases cell life.
View Our Thermal Cell Barrer Case Study
Client Testimonials
What our customer partners think
"Tecman took on the challenge of manufacturing a complex multi-material thermal transfer product. Using innovation, engineering skills and advanced manufacturing capabilities, they took the product from drawing through feasibility and onto production level manufacturing.
I would without hesitation recommend Tecman as a manufacturing partner, whatever challenges they face they overcome them."
Chris Hallsworth
Thermal Management Consultant
--
"I would be very nervous of losing the support
and knowledge they carry."
Senior Development Engineer
At Leading Design and Manufacturing Organisation
Ready to enhance the safety of your battery pack?
Our technical team is ready to demonstrate how our advanced ATP pad technology can help you meet strict safety standards while reducing overall costs.
Advanced Thermal Management Solutions for Battery Development
Learn more
Case Study: Advanced Thermal Cell Barrier for EV Battery Packs
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Thermal Cell Barrier with built in frame
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Encapsulated Thermal Cell Barrier
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Key insights from our thermal management conference session
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