Challenges in insulating battery and the On-Board Charger (OBC)

The rapid global adoption of New Energy Electric Vehicles (EVs) hinges on the reliability and efficiency of their core systems: the high-voltage battery and the On-Board Charger (OBC). However, these systems present significant engineering challenges, primarily concerning thermal management, electromagnetic compatibility (EMC), and the critical balance between safety and lightweight design.

Addressing Key Challenges with Precision Solutions

1. Thermal Management for Power Battery Packs:

• Challenge I: Inconsistent temperatures between cells can accelerate battery degradation and pose a thermal runaway risk. Effective isolation from external heat and internal fire propagation is paramount.

• Our Tailored Solutions:

  • Heat Spreading & Conduction: Our high-compressibility Thermal Conductive Pads are engineered to fill air gaps between individual cells and between the battery module and cooling plate. This establishes an efficient thermal pathway, ensuring uniform temperature distribution and maximizing battery life and performance.

  • Ultimate Thermal Barrier: We integrate Aerogel blankets and sheets into critical areas of the battery pack. As a super-insulating material, Aerogel effectively blocks external heat from impacting the battery and can significantly delay the spread of thermal runaway in the event of a single cell failure, providing crucial time for occupant safety.

  • Insulation & Cushioning: Custom-molded Polypropylene/Polycarbonate (PP/PC) Insulators provide reliable electrical insulation for the Battery Management System (BMS) and high-voltage connections. They offer excellent mechanical strength and resistance to automotive fluids.

  • Sealing & Fire Protection: Our flame-retardant Silicone Foam is used for pack covers and wire harness pass-throughs. It provides superior sealing and damping while acting as a fire barrier, significantly enhancing the overall safety integrity of the battery system.

2. Thermal & EMI Challenges for On-Board Chargers (OBC):

• Challenge II: High-power-density OBCs generate substantial heat from components like MOSFETs and IGBTs. Dissipating this heat directly impacts charging speed and longevity. Furthermore, their high-frequency switching operations generate intense electromagnetic interference (EMI).

• Our Tailored Solutions:

  • Efficient Heat Dissipation: We apply high-thermal-conductivity Thermal Conductive Pads or ultra-thin Thermal Tapes between power semiconductors and the heatsink/casing. Our Thermal Tape is particularly advantageous in space-constrained applications where both strong adhesion and efficient heat transfer are required.

  • Electromagnetic Shielding: Precision-die-cut EMI Shield Gaskets are installed at OBC housing seams and interfaces. These gaskets create a continuous Faraday cage, effectively containing electromagnetic emissions and ensuring the stable operation of the OBC and other sensitive onboard electronics.

Why Choose Us For Your Ideal Strategic Partner?

We understand that superior products must be backed by superior service. In a competitive landscape, we position ourselves not just as a material supplier, but as a trusted and reliable partner. Our core advantages are designed to integrate seamlessly into your supply chain and accelerate your development cycle:

1. Rapid Response & Flexible Supply: We commit to a 30-minute rapid response to all your technical and commercial inquiries. We guarantee on-time and fast shipping and, critically, we accept small-quantity orders. This flexibility is ideal for supporting your R&D, prototyping, and pilot production phases, helping you get to market faster.

2. Stringent Quality & Commitment: Strict QC Procedure, Tolerance Size strictly controlled. Defecective Rate is 100% followed to
   consensual ERP drawing standard, 1:1 replacement or refund for any defectives if happened.

3. One-stop & Customization Services: Our advanced die-cutting customization services for your products. Totally fitting your drawings perfectly. 

Conclusion:

The future of electric mobility demands increasingly rigorous standards for thermal management and electromagnetic safety. By leveraging our integrated portfolio—including Thermal Conductive Pads, Thermal Tapes, PP/PC Insulators, EMI Gaskets, Aerogel, and Silicone Foam and other products, we are committed to providing you with a series of solutions for all aspects of new energy vehicles. Welcome to feel free to leave us your messages!