Pioneering scalability & innovation in EV thermal management

As EV adoption increases, OEMs are facing market demands for vehicles that are more reliable and have improved range. This requires innovation in both material selection and manufacturing processes.

Tecman have a proven track record of working with OEMs to help them address these challenges by developing new solutions using existing high-performance materials in more innovative ways.

(Above) Framed Anti-Thermal Propagation pads with built-in spacers for prismatic battery cells.

By leveraging our industry knowledge and cross-sector expertise, we are helping customers to produce safer, better performing EV batteries that improve energy density and provide competitive cost per kWh outputs.

Innovative material applications to enhance EV performance

We are finding that OEMs are increasingly looking for solutions that balance innovation and scalability. They want innovative materials that can deliver against a challenging specification, but they also want solutions to be practically implementable on a global scale.

As McKinsey highlight, most parts in EV vehicles will remain the same as they were in internal combustion engine (ICE) vehicles¹ – OEMs are therefore rightly asking their supply partners, ‘how can we repurpose or adapt materials we have already specified?’.

Tecman have a focus on designing for high volume manufacturing; it is a consideration built into the way our engineering teams work. Our bespoke solutions are designed to meet complex technical requirements and be suitable for large scale roll-out. It is this end-to-end support that has seen us develop a strong reputation within the industry.

It is the application of existing materials in new and innovative ways that offer OEMs scalable solutions within lean cost parameters, though specific and novel material innovations like nano-enhanced fluids also play an important role.

Effective thermal management is important for battery safety, efficient energy usage and component longevity. If managed correctly, cell life can be enhanced and performance optimised. Insulating batteries, enabling thermal transfer away from a cell and supporting cells to perform when rapidly heated and cooled, requires a rethink in how different materials are used in the production process.

Material innovation isn’t just about thermal management though; adhesives can be used to bond aluminium, carbon fibre composites and steel to reduce vehicle weight and enable batteries to perform more effectively.

This is why we work closely with customers to understand their wider objectives – what is it they are trying to achieve? There are sometimes surprising ways of achieving the same goal.

Leveraging proven cross sector expertise to drive EV innovation

One of the ways we add value to customer projects is by drawing on our cross-sector expertise. Our skilled engineers work across automotive, electronics, life sciences and wind projects, which helps us to cross pollinate innovation throughout our business.

It is often the case that a methodology or material is already being used successfully in another industry, but customers have not yet experimented with its use in their industry. We have helped automotive customers to innovate by applying lessons in thermal management from the electronics sector to the EV sector, for example.

Proven Partner: Surpassing customer expectations with collaboration & advanced processes

The most appropriate solution will depend on an OEM’s precise specification and the intended end use. Is the primary concern to reduce thermal runaway? Extend range? Improve performance for a high-end vehicle?

As a result of our strong industry partnerships, Tecman has access to a wide library of materials with different properties, so we are able to assess their suitability against end use conditions. This involves factoring in considerations like temperature, erosion and lifespan to ensure materials work in multiple settings, for example with both prismatic and pouch cell solutions.

(Above) Encapsulated anti-thermal propagation pads for pouch cells use a combination of existing advanced lightweight material technology. 

We see collaboration with customers as essential, as it leads to the co-creation of more innovative solutions that meet challenging specifications and requirements.

Innovation is not just about the final component, but about processes too. Our state-of-the-art manufacturing facility in the West Midlands is IATF certified and uses a combination of all-in-one automated processes and continuous production techniques to improve efficiency and deliver cost competitive solutions for our customers.

Unlock innovation in your battery development project

Whether your aim is to reduce thermal runaway, extend range, or optimise high-performance vehicles, our team is ready to understand your challenges and work closely with you to engineer a custom thermal management solution. Contact a Tecman expert today to discuss your thermal management application. 

Contact a Tecman Expert