EV Battery Die Cut Solutions
CFS is a leader in the converter market, leveraging advanced technologies to provide die cut solutions for electric vehicle (EV) battery components. As a 3M Preferred Converter holding ISO 9001:2015 certification, our systems are set up to meet the strict demands of the automotive industry.
Electric vehicle (EV) batteries are made up of several components – many of which use die cut parts. The battery cells, battery modules, battery packs and battery management system (BMS) contain one or more of the following: compression pads, thermal interface components, gaskets and seals, flame barriers, thermal runaway/anti-propagation, electrical insulation and barriers, EMI shielding and adhesive joining and bonding.
At CFS, we can work with electric vehicle (EV) manufacturers, OEMs, and suppliers to engineer custom converted and die cut solutions that meet the unique production challenges of the EV market. Read on to learn about how we can help with creating the right die cuts for your battery or EV application.
1. Enhancing Battery and EV Safety with Advanced Thermal Runway Protection
Preventing and suppressing thermal runaway propagation within battery cells and modules is crucial for ensuring the safety of batteries and electric vehicles. As a 3M Preferred Converter, CFS has access to a comprehensive range of barrier materials designed for various applications, including placement above and between cells, underlids, and between modules.
Many of these barrier materials also function as effective insulators. Our selection includes inorganic paper and board materials specifically engineered to mitigate thermal runaway propagation. Additionally, we convert a variety of anti-propagation materials such as Formex®, Lexan, polyimide films, fibrous papers, felts, intumescent foams, and composites, offering tailored solutions to meet safety and performance requirements.
2. Thermal Management for EV Batteries
To support the higher voltages and extended range needed in EV battery designs, CFS partners with 3M to apply advanced thermal management solutions. Integrating these solutions into your designs helps enhance battery life, improve range, reduce recharge times, and streamline assembly processes.
Die-cut thermal interface components facilitate efficient heat transfer within the battery cell, pack, and module. CFS converts materials for thermal gap pads, compression pads, phase change materials, and graphite components, providing effective solutions for thermal management and extending battery longevity.
3. EV Die Cut Assembly Solutions
The assembly of EV batteries is centered on performance—optimizing design efficiency, material selection, and serviceability for both production and end users. 3M bonding solutions offer adhesives that provide semi-structural and structural strength, making them ideal for use alongside or as replacements for mechanical fasteners. Our range of tapes ensures excellent electrical insulation in precise locations. 3M structural adhesive tapes are particularly beneficial for applications that do not require initial adhesive curing times. We offer single-sided film, transfer, and double-sided tape constructions, including flame-retardant options. Video example.
Critical Battery Module and Pack Sealing
Sealing the battery module and pack is essential for ensuring optimal performance. Battery components are enclosed between upper and lower housings, with seals and gaskets playing a vital role in protecting sensitive components from water, dust, and air ingress. Additionally, these seals help contain hazardous materials in case of a collision. The selected gasket and seal materials must endure extreme temperatures and often need to be UL94 V-0 rated, successfully passing horizontal and vertical burn tests. Visit our die-cut gaskets page to learn more.
Importance of Compression Pads and Spacers
Compression pads and spacers are key elements in EV battery design. They secure battery cells in place while allowing for necessary expansion and contraction during operation. These components must be firm enough to provide adequate support while maintaining compression, ensuring battery longevity and stability. Designed for cushioning between cells in electric vehicles, microcellular polyurethane cushioning foams are rigorously compression tested to deliver consistent, moderate pressure as battery cells swell and contract during charging cycles. At the cell level, controlled compression mitigates performance issues caused by high or uneven pressure distribution.
4. EMI Shielding
With decades of experience in developing electrically conductive solutions for consumer electronics, industrial, and avionics applications, CFS offers grounding and shielding tapes engineered to endure the demanding conditions of electric vehicle battery systems. These tapes withstand temperature extremes, humidity, shock, vibration, and more—ensuring reliable EMI/RFI management throughout the vehicle's lifespan. Learn more.
Advanced EMI Shielding and Protection
We source specialty, electrically conductive adhesive transfer tapes (ECATTs), metal foil tapes, and metallized fabric shielding tapes from 3M and other suppliers, which are designed to block electromagnetic interference (EMI) across a broad frequency range. These materials maintain consistent performance in harsh environments, keeping battery components functioning optimally and aiding in regulatory compliance.
High-Performance Grounding and Shielding Solutions
Grounding and shielding tapes feature pressure-sensitive acrylic and silicone adhesives, catering to global markets such as electronics and automotive. Engineered with conductive particle fillers, these tapes offer low and stable contact resistance, uniform conductivity, and strong adhesion in extreme conditions. Electrically conductive foil and fabric tapes incorporate durable copper or aluminum foil or metallized polyester fabric carriers.
Applications in EV Battery Systems
3M ECATTs, electrically conductive foil tapes, and fabric tapes are ideal for multiple EV battery applications, including:
-Battery module and cooling plate grounding
-Battery cover grounding and shielding
-Battery management system (BMS) grounding and shielding
ECATTs come in various adhesion strengths, with high adhesion options for production processes requiring secure hold and standard adhesion for easier rework during assembly. Additionally, electrically conductive adhesive transfer tapes are available with different adhesion levels on each side. Featuring easy-release or tight-release film liners, they support staged assembly and are compatible with automated equipment for efficient processing.