Lightweight Insulation: Electric-Vehicle Batteries

Formex brand electrical insulation material meets the demanding requirements of electric-vehicle design and manufacturing.

Battery systems in electric vehicles include demanding environmental, mechanical, and chemical requirements while emphasizing safety and weight reduction.

Formex electrical insulation material meets all of the following requirements for automotive battery cover material:

• Lightweight
• Inexpensive
• Flame retardant
• Resistant to most battery chemistries
• Strong and reliable (to reduce OEM costs under maintenance service agreements)
• Meets rigorous electrical barrier and insulation requirements

Unlike materials that need to be molded into parts, Formex is easily and economically formed into complex three dimensional parts by:

• Die-cutting
• Scoring
• Bending

Formex delivers superior performance in comparison to other battery cover materials such as aramid paper. Aramid paper absorbs significantly more moisture, is less dimensionally stable, is more expensive, and does not provide score and fold capabilities. Because Formex is a better electrical insulator, thinner product can be used to reduce weight.

Its long-term thermal aging capabilities have been long recognized in other applications, making Formex ideal for reliable service in automotive environments.