Thermal Cell Barrier with built in frame

Highly efficient Industry leading manufacturing system for OEM approved Framed Anti-thermal propagation (ATP) pads

 

The Industry Challenge:

Improving the safety and performance of battery packs using a cost-efficient cell barrier designed for scale

Battery pack manufacturers, whether automotive or energy storage, face similar challenges with cell life and performance. For thermal barriers between battery cells to be completely effective, they must perform three main functions. In doing so, they secure the safety of the pack and provide optimum performance and life expectancy of the cells.

09 Prismatic Cell To Insulation Material Mounting

Firstly, the barrier should prevent the propagation of thermal energy from a cell in thermal runaway to its neighbouring cell. The best performing barriers will prevent this propagation altogether allowing the cell to expend its energy without triggering thermal event in the neighbouring cell.

Secondly the cells require space to expand and contract during service including rapid charge which puts significant strain on the cell. The cell barrier should provide this space to allow for the cell movement.

Finally, cell barriers should also provide a degree of mechanical resistance to the wall of the cell during expansion and support the contraction of the walls in a controlled manner. This enhances cell performance and overall life of the cell.

There are various ways that engineers achieve this, however, the challenge is how to produce a single piece thermal cell barrier with a built-in spacer in a cost-efficient production method that delivers extreme high volume.

That's where Tecman comes in.

The Industry Solution:

Cost effective all-in-one manufacturing system for advanced thermal cell barriers with built-in spacers

Tecman has developed a highly efficient manufacturing process for the manufacture of OEM approved advanced cell barrier technology with built-in spacers. 

The Framed Anti-thermal Propagation (ATP) Pad is an advanced thermal cell barrier that incorporates a physical built-in spacer surrounding the thermal insulation pad, providing optimal space between battery cells and enabling the mechanical properties of the insulation material to absorb cell expansion.

Tecman Framed ATP Pad - Thermal Cell Barrier 2

Framed ATP Pad

The materials used within the Framed ATP Pad can be interchanged depending on the application requirements. We can develop a bespoke solution using a combination of the clients’ specified materials or our own selection of materials.

1. The Insulation Material - This critical material used within the Framed ATP Pad provides insulation between cells using anti-thermal propagation technology to prevent thermal propagation in a thermal runaway event. It also provides the mechanical resistance to the wall of the cell during expansion and supports the contraction to original state.

2. The Spacer Frame - The in-built frame works to optimise the space between the cells, allowing the cells to expand and contract during service condition.

3. The Adhesive Tape - This has three important functions within the Framed ATP Pad. It bonds the pad onto the battery cell to secure it during assembly, it improves the vibration and shock performance by holding the cells together adding stiffness to the pack, and it works to encapsulate the insulation material.

Request a consultation for further information

Framed ATP Pad And Manufacturing Process V1

The manufacturing System

The compact production line has a very small footprint, making it suitable for integrating into existing clean production facilities or in a small, dedicated production space located close to the battery assembly line.

The process eliminates the need for third-party pre-conversion of the component parts enabling uninterrupted, continuous running. Each machine has the capability of producing up to 120 parts per minute.

By running continuously across shifts, it is a cost-effective, high-volume production line with a capacity to manufacture up to 36 million parts per annum.

Framed ATP Pad system manufacturing speeds

Manufacturing Process Features & Benefits
Features   Benefits
all in one process

ALL IN ONE PROCESS
The machine is loaded with slit rolls of material and converts the components parts required within the Framed ATP Pad within the same manufacturing process.

  • Eliminates the need for 3rd party conversion of component parts

  • Lower material input costs

  • Reduced input material complexity

  • Reduced production times.

continuous-production

CONTINUOUS PRODUCTION
The production line is one continuous manufacturing system that runs without stopping.

  • Maximise OEE

  • No downtime for roll changes

  • In-line closed loop adjustments

  • 100% part inspection.

small-footprint

SMALL FOOTPRINT
The manufacturing production line is a compact unit that fits inside a small production space without needing an entire factory.

  • Reduces cost impact when situating in clean manufacturing area

  • Allows location in close proximity to battery assembly plants.

flexible-material-option

FLEXIBLE MATERIAL OPTIONS
The manufacturing process is capable of processing different materials.

  • Flexibility to produce multiple Framed ATP Pad solutions

  • Option to use customers’ specified materials or Tecman’s proven materials.

multiple-size-options

MULTIPLE SIZE OPTIONS
Capable of producing multiple size parts to suit the requirement of the battery cell.

  • Suitable for multiple prismatic cell solutions

  • Effective for EV battery and battery storage systems.

Key benefits

Framed ATP Pads

  • Termal B
    Thermal cell barrier with built in spacer
  • Protect From Thermal Shock
    Protects against thermal runaway event
  • Improves Safety
    Improves safety of the battery system
  • Improve Service Battery Life
    Extends cell life within battey packs
  • Optimises Performance
    Optimises performance of the battery
  • Lightweight
    Lightweight solution

All-in-one Process

benefits
  • All-in-one process for manufacturing advanced cell barriers with built-in spacers
  • Manufacturing speeds of up to 36 million parts per annum
  • Continuous cost-efficient production line
  • Extreme high volume
  • Integrates into existing facilities
  • Shortens supply chain
  • Flexible solution tailored to requirements

case study in action

Delaying thermal propagation by over 20 mins in EV battery packs

Tecman Framed ATP Pad - Thermal Cell Barrier 2

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.

 

read the Framed ATP Pad case study

FRAMED ATP PAD BROCHURE

Solving thermal management challenges with industry leading manufacturing system

TECMAN ATP PAD

OEM approved thermal cell barrier technology

Annotated ATP Pad Portrait Labels Only

For pouch and solid state cells

We also manufacture Anti-thermal Propagation (ATP) Pads, which are OEM approved thermal cell barriers for pouch and solid state battery cells. The manufacturing system uses a similar method to the Framed ATP Pads, delivering the same cost-efficiencies and extreme high-volume.

The ATP Pad prevents the propagation of thermal energy from a cell in thermal runaway, securing the safety of the battery pack and providing optimum performance and life expectancy of the cells. The encapsulated design is optimised for assembly processes and prevents insulation material particles from entering the environment. 

The innovative manufacturing process for the ATP Pad eliminates the need for third-party pre-conversion of the component parts enabling uninterrupted, continuous running of up to 120 parts per minute from a single machine.

The very small footprint of the production system makes it suitable for integrating into existing facilities close to the battery assembly line.

Learn more about Tecman's ATP Pad

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