Enhancing New Energy Vehicle Safety With High-Temperature Insulation Materials

The rapid growth of the new energy vehicle (NEV) industry has established it as a crucial direction for the future of transportation, thanks to its advantages in low-carbon emissions and energy efficiency. However, safety remains a core challenge. As the central component of electric vehicles (EVs), battery packs operate under complex conditions and face risks such as high temperatures, short-circuit arcing, and electrolyte leakage-especially during accidents. These risks can trigger thermal runaway, causing rapid propagation and posing serious threats to both vehicles and passengers. High-temperature insulation design is essential for improving battery pack safety, making it a vital area for technological advancement.

Key Considerations for High-Temperature Insulation Materials:
To achieve advanced safety for battery packs, several technical challenges must be addressed. The following factors are critical in developing effective high-temperature insulation solutions:
High-Temperature Insulation Capability: Insulation materials must maintain stable performance under extreme conditions to prevent accident escalation caused by thermal runaway, whether due to electrical, thermal, or mechanical abuse.
Electrolyte Corrosion Resistance: Insulation materials must exhibit exceptional resistance to high-temperature electrolytes, which can cause rapid degradation through short-circuit arcing or slow material corrosion over time.
Long-Term Reliability: Insulation materials must offer excellent aging resistance to endure complex environments and extend battery pack service life.
Ease of Installation: Efficient processing and easy installation are crucial for accommodating complex structural designs, simplifying assembly, and enhancing production efficiency to balance safety with industry demands.

Futureway High-Temperature Insulation Solutions
Futureway Technology has pioneered a suite of high-performance silicone rubber composite materials to enhance the safety of battery packs. These solutions ensure superior electrical insulation under extreme temperatures, safeguarding battery packs' stability and safety.
1. Solutions for Busbars and Connectors
Busbars and connectors, essential for current transmission in battery packs, face challenges from high temperatures, arcing, and electrolyte corrosion. Futureway high-temperature insulation tapes provide comprehensive protection with the following features:
High-Temperature Insulation: Maintains stability under extreme temperatures, preventing electrical fault propagation.
Fire Resistance: Passes rigorous flame-retardant tests to enhance safety.
Electrolyte Corrosion Resistance: Resists harsh conditions such as electrolyte ejection.
Ease of Processing: Flexible design accommodates complex structures for efficient assembly.

2. Solutions for Wire Harnesses
Wire harnesses, critical for electrical connectivity, must endure high temperatures, electrolyte leaks, and mechanical vibrations. Poor insulation can disrupt signals, cause electrical shorts, or malfunction control systems. Futureway high-temperature insulation sleeves offer:
Wide Temperature Range Adaptability: Stable performance from -55℃ to 200℃ and resilience under 800℃ temperature shocks.
Abrasion and Tear Resistance: Stable performance from -55℃ to 200℃ and resilience under 800℃ temperature shocks.
Chemical Corrosion Resistance: Prolongs lifespan by resisting electrolytes and chemicals.
Flexibility for Installation: Accommodates complex routing with efficient installation.

3. Solutions for Structural Components
Structural components such as trays, end plates, covers, and casings must maintain insulation during arcing, short circuits, and thermal runaway. Futureway high-temperature insulation sheets provide:
Reliable Insulation at 1300℃: Ensures system stability under extreme conditions.
Electrolyte Corrosion Resistance: Prevents performance degradation from prolonged exposure.
Lightweight, Flexible Design: Ultra-thin materials ensure coverage of complex components while reducing battery pack weight.
Mechanical Strength and Cushioning: Reinforced fire-resistant fabrics offer tensile and tear resistance. The TIX-30 insulation sheet delivers elasticity between -55℃ and +200℃, providing cushioning for structural components.

Driving Innovation for Safer electric vehicles
Through material innovation and technological breakthroughs, Futureway Technology has developed advanced high-temperature insulation solutions that meet the stringent safety requirements of electric vehicle battery packs. By prioritizing customer needs and exploring the forefront of material technology, Futureway continues to deliver cutting-edge solutions for the EV industry, paving the way for safer, more efficient transportation.