Marian is a world leader in manufacturing die-cut electric vehicle (EV) battery components for both the automotive and electronics industries. With ISO 9001 and IATF 16949 certifications, Marian’s quality management systems are set up to meet the strict demands of the transportation industry. Marian can provide rapid turnaround on material samples and prototypes while also offering design assistance and collaboration.
Innovative Die-cut Solutions for EV Battery
Battery/EV Solutions
Battery Cell
The battery cell, the basic energy producing unit of the EV battery, must endure shock transmitted during driving and withstand high and low temperatures.
Marian Solutions:
- Compression pads
- Thermal interface components
- Insulators/barriers
- Flame barrier
- Anti-propagation/thermal runaway
Battery Module
A stack of cells are assembled into a frame and contained in a module to protect contents from heat and vibration.
Marian Solutions:
- Joining
- Insulator/barriers
- Thermal interface components
- Gaskets/seals
- Flame barrier
- Anti-propagation/thermal runaway
Battery Pack
The modules are assembled into a final package with various control/protection systems such as a battery management system (BMS) and a cooling device.
Marian Solutions:
- Gaskets/seals
- Thermal management
- Insulators/barriers
- Cooling insulation
- Anti-propagation/thermal runaway
Battery Management System (BMS)
The Battery Management System’s primary functions include provisions for increased safety during charge/discharge, longer life, state of operation (including state of health and state of charge), and monitoring temperature and cell imbalance. BMS communicates, computes, monitors, and protects the battery pack.
Marian Solutions:
Charging
EV Charging systems are complex electrical enclosures. Charging stations and plugs are exposed to environmental elements such as rain, snow, ice, wind, and an extreme range of temperatures. The enclosures must meet specific industry standards including UL and IP ratings. Additionally, the high electrical current and sophisticated electronics of the system create potential for electromagnetic interference issues.
Marian is a leader is manufacturing custom high-quality gaskets that will protect sensitive components from moisture, dust, and electromagnetic interference for the long life of the EV charging system.
- Rogers BISCO® Silicone Foam
- Rogers PORON® Polyurethane Foam
- Rogers PORON® AquaPro™
- Saint Gobain Norseal® Foams
- Acrylic foam tapes (3M™ VHB™, tesa® ACXplus)
- EMI/EMC materials: copper and aluminum foils; conductive tapes and foams
Marian Solutions:
Die-Cut Components for EV Batteries
1. Thermal Management
Batteries produce heat when charged or discharged. This heat must be removed, as excess heat can reduce the battery’s performance and limit the life of the battery. Die-cut thermal interface components provide effective heat transfer within the battery cell, pack, and module. Marian manufactures thermal gap pads, phase change, and graphite components to solve these issues and to increase battery life. Key thermal management material suppliers include 3M, tesa®, Saint-Gobain, Neograf, and Polymer Science.
Additionally, prevention and suppression of thermal runaway propagation within battery cells and modules ensures battery and EV safety. Marian converts a variety of flame-resistant materials that meet specific UL requirements. Some materials include 3M™ Flame Barrier, ITW Formex®, and Rogers BISCO® Silicone Foams.
Check out this Webinar! In October 2022, Marian teamed up with the team at tesa® to present a webinar as a part of the Charged EV Virtual Engineering Conference. The topic addressed was ‘Managing Heat in EV Battery Packs with Adhesive Tapes and Precision Converting’. Register to view here.
2. Seals + Gaskets
The sealing of the battery module and battery pack is critical to its operation. EV battery components within battery modules and packs are often enclosed between upper and lower housings. Seals between these two housing elements protect sensitive components from water, dust, and air ingress. Seals also assure any dangerous materials are contained in the event of a collision. Selected gasket and seal materials must withstand extreme temperatures and are often required to be UL94 V-0 rated, passing horizontal and/or vertical burn tests.
Marian can be a great help in material selection. We maintain strong partnerships with leading raw material manufacturers such as Rogers Corporation, 3M, Zotefoam, and Armacell. Rogers BISCO® Silicone, PORON® Urethanes, and Saint-Gobain Norseal® Foams are excellent for EV battery gaskets and seals. These materials exhibit great compression set resistance while offering long-term proven performance at extreme temperatures. 3M™ VHB™ double-coated acrylic foam tapes can also be used to join and bond materials while sealing out moisture and dirt.
Visit our Gaskets & Seals page to learn more.
3. Dielectric Barriers + Insulators
Dielectric barrier materials and flame barrier films are integrated into the battery components to meet rigorous electrical barrier and insulation requirements to keep the battery running safely. These materials often double as thermal barriers and insulators as well. Materials are lightweight, flame retardant, and easily converted to meet unique application requirements. Marian manufactures custom components from materials such as ITW Formex®, Lexan™ films, Kapton® Polyimide films, and 3M™ EMI/EMC materials.
Visit our Electrical Insulation page to learn more.
4. Spacers + Compression Pads
Compression pads and spacers within the battery module must be firm enough to hold the battery cells in place while also maintaining compression as the cell expands and contracts. They must also exhibit long-term performance at a range of extreme temperatures and conditions. Marian is a leading converter for many compression pad foam materials including Rogers PORON® polyurethane, Rogers BISCO® silicone, and other neoprene-based foams.
Rogers PORON® and BISCO® are ideal for battery cell pads because the material offers reliable compression set resistance and stress relaxation performance over a broad range of temperatures and conditions. Additionally, foam pads also isolate and dampen noise and vibration (NVH/BSR) caused by vehicle operation.
5. EMI Shielding
Maximize performance of batteries and other electronics within the vehicle by shielding against electromagnetic interference. A large electromagnetic field is often produced by the operation of the battery and connecting cables. This can interfere with other electronics within the vehicle. Conductive elastomers, foils, seals, and pressure sensitive adhesive components can help properly shield from EMI. Marian manufactures converted parts with copper foils, aluminum foils, and conductive PSA. Key EMI/EMC material suppliers include 3M, Polymer Science, and Saint-Gobain.
Visit our EMI Shielding and Grounding page to learn more.
6. Anti-Propagation
Enhancing safety is becoming increasingly urgent for electric vehicle development. Li-ion batteries produce a significant amount of heat while in use and while charging. Along with the use of thermal management materials, placing extremely high temperature-resistant materials between the components of the battery cell, module, and pack can assist in mitigating thermal runaway. Materials include films, fibrous papers, felts, intumescent foams, and composites.
7. Flame-Retardant Adhesives Tapes
Marian’s partnership with the top adhesives producers globally allows us to offer the largest assortment of flame-retardant pressure sensitive adhesive tapes. Growing demand from OEMs are that all components within the pack be UL rated, and adhesives are no exception. Single-sided film, transfer, and double-sided tape constructions are all available as flame-retardant options.
Blog Posts
- 4 Insulating Materials for use in EV Batteries
- Complex Electric Vehicle Battery Components
- Why P-THERM® Gap Fillers Are Essential for EV Battery Design
- The Best Thermal Gap Pad for Your Design
- 4 High Performance Thermal Barrier Materials for EV Battery
- PORON® EVExtend For Use In EV/HEV Li-ion Pouch Cell Batteries
- 11 Considerations When Selecting TIM for EV Li-ion Battery
Related Resources
Solution Case Study: Rogers PORON® Helps EV Manufacturer Solve Charge Plug Problem
In this success story from our trusted material supplier, Rogers Corporation, an electric car manufacturer found a leak in the charging plug enclosure during pre-launch testing. Rogers provided a gasket made with PORON® AquaPro 37™, which has an excellent compression set resistance. The new and improved gasket will seal out moisture for the life of the automobile.