As electric vehicle (EV) manufacturers adopt higher voltage battery architectures to enhance faster charging and enhanced performance, they must confront growing thermal and electrical challenges. These challenges include overheating and thermal runaway, short circuits and system failures, electromagnetic interference (EMI) and the loss of signal integrity, and overall performance loss.
To address these risks to passenger safety, enhance vehicle operability, and long-term battery performance, engineers must effectively dissipate heat, enhance reliable high-voltage insulation, and enhance protection of components from mechanical stress – all while minimizing weight and maximizing space efficiency within EV battery architectures.
With a comprehensive materials portfolio, Qnity empowers design engineers to address these interconnected challenges. Advanced polyimide films enable high dielectric strength and thermal stability across wide temperature ranges, meeting the needs for enhanced electrical insulation and thermal management. Thermal interface materials – including gels, greases, and gap fillers – efficiently transfer heat away from battery cells to cooling systems, enabling the maintenance of optimal operating temperatures and reducing the risk of performance degradation.
To enable robust electrical connectivity between cells and throughout the battery system, Qnity’s metallization solutions enhance conductivity and resist corrosion in power connectors. Flexible circuit laminates enable compact, lightweight battery management system (BMS) designs while providing flame-retardant properties for added safety. EMI shielding gaskets reduce interference and provide environmental sealing, while pressure-sensitive insulation materials help to reduce the risk of short circuits and electrical arcing.
As the automotive industry advances toward 800V architectures, higher energy density, faster charging speeds, and cell-to-pack and cell-to-body designs, engineers need cutting-edge materials solutions to enable safety, efficiency, and long-term reliability. Drawing on Qnity’s high-performance materials and integration expertise, automotive design engineers can develop safer, lighter, and more sustainable EV battery systems.
Explore Qnity’s assembly and packaging solutions for EV battery systems in the graphic below.
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