EV India

Innovative Solutions for Safer and More Efficient EV Battery Packs


The adoption of electric vehicles (EVs) is vital to address the climate crisis. As the auto industry embraces EVs, the demand for EV battery packs is surging. Researchers are developing new materials and composites to enhance battery chemistry and improve performance, leading to longer runtimes, better performance at higher temperatures, and greater vehicle ranges.

Understanding the Current Landscape of the EV Battery Market

The Indian electric vehicle battery market is poised to grow at a significant rate, according to a recent study. The growth is attributed to increasing demand for electric vehicles, driven by environmental concerns, rising fuel prices, and supportive government policies. For the widespread adoption of EVs, longer-lasting, high-power batteries are essential.

By Ritesh Patterson, General Manager, Performance Plastics

By Ritesh Patterson, General Manager, Performance Plastics

Lithium-ion (Li-ion) batteries offer superior power density and charging capabilities but have short operational lives and degrade quickly. When it comes to Pouch and Prismatic cells, maintaining optimum pressure during battery “breathing” cycles can improve the battery lifespan from BOL to EOL of these cells.. Innovative materials are available today to design and develop safer and more efficient battery packs across different cell types, which would make it easier to adapt and sustainable.

Innovative Materials Driving the Shift from Tape Solutions in the EV Market

Compression and cushioning pads are essential for EV battery packs to ensure consistent and predictable pressure during charge/discharge cycles starting of BOL to EOL of cells mainly in Pouch & Prismatic cells. Silicone and micro-cellular polyurethane (PUR) materials are the most preferred in these applications given its consistent performance over a larger time period. As design demands, Thermal runaway protection materials which can serve a dual purpose of thermal insulation with fire-blocking characteristics and excellent compression set resistance needed for compression pad. UL94 V-0 tested IP67 battery pack sealing options to meet IP67 ranges from foam-in-place gasketing to silicone foam rubbers to butyl-coated PVC and micro-cellular PUR foams. Thermal interface materials remove excess heat from battery pack cells to improve battery performance and extend battery life.

Exploration of materials for EV battery protection.

Electric vehicles (EV) require battery pack protection solutions that address extreme conditions of temperature, smoke, fire, air and water that are encountered. With safety and performance being top priorities, new innovative solutions are under development to meet extreme requirements to address thermal runaway and cell deformation factors between BOL to EOL of battery. When these solutions are considered for the design it enhances safety in addition to performance by increasing overall life of the battery. 

However market is evolving at much faster pace and which calls for continued innovation in the segment.

Transforming the Future with Advancements in EV Battery Packs

Advancements in battery technology have brought us closer to safer and more efficient EV batteries. From battery balancing technology and innovative packaging to increased battery density, there are several inventive solutions that can help enhance the performance of EV battery packs.

These solutions are paving the way for an increasingly electric future. As more automakers and battery makers incorporate these advancements into their designs, the EV industry can move closer to the goal of a safer and more efficient electric vehicle ecosystem.

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