Thermal Cell Barrier

Highly efficient Industry leading manufacturing system for OEM approved 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 secure the safety of the pack and provide optimum performance and life expectancy of the cells.

09 Prismatic Cell To Insulation Material Mounting Cropped

Critically 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 a thermal event in the neighbouring cell.

Additionally, the advanced insulation materials that are ideal for this application can be dusty, fibrous and delicate. Therefore, the ideal solution must ensure that no debris or particles from the insulation material are introduced into the battery pack or assembly environment. Whilst ensuring that the delicate structure of the insulation material is not damaged and its performance compromised.

There are various ways that engineers achieve this, however, the challenge is how to produce a debris-free single piece thermal cell barrier optimised for easy assembly, 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

Tecman has developed a highly efficient manufacturing process for the manufacture of OEM approved advanced thermal cell barrier technology, the Anti-Thermal Propagation (ATP) Pad. The ATP Pad is an advanced single-piece thermal cell barrier manufactured in a cost-efficient production method that delivers extreme high volume.

Annotated ATP Pad Portrait Labels And Descriptions

Tecman ATP Pad

The materials used within the 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. Lightweight Advanced Insulation Material - The advanced insulative materials used within the ATP Pad provide insulation between cells using anti-thermal propagation technology to prevent thermal propagation in a thermal runaway event.

2. Encapsulation film - Provides dielectric breakdown resistance, reduces debris and aids with the handling of the pads during assembly processes. 

3. Double-sided tape for bonding to cell with an adhesive liner. This bonds the pad onto the battery cell to secure it during assembly and improves the vibration and shock performance by holding the cells together adding stiffness to the pack.

The manufacturing process provides the flexibility to customise the materials of the ATP Pad, allowing for customer-specified materials and/or proven materials selected by Tecman's material engineers.

SPEAK TO AN EXPERT ABOUT THERMAL CELL BARRIERS

Thermal Cell Barrier Text Block Insulation Mat Replacement

superior ultra-lightweight thermal insulation materials to prevent thermal-runaway

Our Advanced Material Engineers are constantly researching and testing innovative thermal management materials and select the most suitable materials during the development of ATP Pad solution.

We can integrate customer specified materials and also guide you through the complex material selection process. Previous material recommendations for ATP Pad solutions include insulation materials such as ceramics and aerogels with cutting-edge performance.

These ultra-lightweight insulation materials have the highest thermal insulation to weight value of any material available on the market. They are most effective materials for the prevention of thermal propagation in a thermal runaway event.

Learn more

Manufacturing Process And Atp Pad 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 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 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 pouch and solid state battery cell solutions

  • Effective for EV battery and battery storage systems.

Key benefits

ATP Pads

  • Termal B
    Thermal cell barrier
  • 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 battery 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
  • 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 solutions tailored to requirements for pouch and solid state battery cell packs

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

Advanced thermal cell barrier with built-in spacer

Tecman Framed ATP Pad - Thermal Cell Barrier 2

for prismatic cells

We also manufacture thermal cell barriers with built-in frames, Framed Anti-Thermal Propagation (ATP) Pads, designed to optimise space between battery cells to improve performance and extend cell life.

The Framed ATP Pad is an advanced thermal cell barrier that incorporates a physical built-in spacer surrounding the thermal insulation pad. During service including rapid charge the cells require space to expand and contract which puts significant strain on the cell.

The Framed ATP Pad provides optimal space to allow for the cell movement and gives a degree of mechanical resistance to the wall of the cell to absorb expansion and support the contraction of the walls in a controlled manner. This enhances cell performance and overall life of the cell.

The all-in-one process for manufacturing Framed ATP Pads is a continuous cost-efficient production line with manufacturing speeds of up to 36 million parts per annum achieving extreme high volume.

Learn more about Tecman's Framed ATP Pad

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