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.
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.
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.
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 rigidity to the pack, and it works to encapsulate the insulation material.
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.
|Manufacturing Process Features & Benefits
ALL IN ONE PROCESS
FLEXIBLE MATERIAL OPTIONS
MULTIPLE SIZE OPTIONS
Framed ATP Pads
Solving thermal management challenges with industry leading manufacturing system
A concept-to-manufacture solution for a major automotive OEM to prevent thermal propagation in EV battery packs. The result was a Framed ATP Pad solution with a thermal propagation delay of over 20 minutes, which is utilised across their entire EV range.View Case study
OEM approved thermal cell barrier technology
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.