Discover how they faced their challenges of producing EVBs by tapping into our expertise and putting strategies into place that resulted in tangible successes. 

Electrified with Avery Dennison: interconnected

In the following examples, we will show you how our solutions are utilised for various applications such as dielectric strength, fire safety barriers and flame-retardancy. 

The first of two featured requests came from an OEM through our label converter partner, who believed that we would be the right specialist in material science to handle this particular challenge. In our second case, the request came from the engineers working for an OEM in the European premium segment via an inquiry through our online channel.

This combined case study illustrates the journey of clients working with divisions of Avery Dennison Materials Group, demonstrating the seamless integration and benefits of engaging with multiple business units within our company simultaneously. Moreover, it showcases the kind of innovative solutions we offer for typical challenges faced by the industry.

The challenge

The request – or rather a set of requests – related to a very specific set of CTQs that had to be addressed on our pressure-sensitive label material. CTQ or ‘critical to quality’ refers to key attributes of a product or service that customers have defined as being important. 

The inquiry was related to specific functional features of labels materials to achieve:

• Flame retardancy, specifically norm UL94 at level of VTM-0 to VTM-2;

• ESD (electrostatic discharging): to avoid generating any sparkle in the electronic devices and around batteries where the label needs to be present for warning, track and trace applications;

• Higher dielectric strength of the material;

• Higher chemical resistant material that can handle aggressive chemicals up to acetone together with accommodating imprints on top of the facestock.

The solution

Given the assignment of the first case, we immediately offered to use our top coating capabilities for PET materials to address the label issues. We added a functional layer to PET core that improves the performance of the material related to the specific requested attributes. These functional coatings cover a wide range of functionalities – including allowing inks to stick better (wettability) to vapour barrier, electromagnetic reflectance (UV and heat reflecting window films), conductivity, vapour barrier, electrical surface resistance and flame retardancy. 

PET is a versatile polymer film, offering a good blend of mechanical strength, temperature resistance and cost. In instance, one case involves a coating that contributes to flame retardance and ESD, the other to the flame retardance and surface resistivity.

We already have a broad portfolio of pressure-sensitive material that can be used in the exterior and interior of the car. As we like challenges, we always welcome new ideas for making our materials even more durable and functional. Any new application we try to address with commercial sense for making it an attractive solution.

The benefits

The construction of the label material was tested against the CTQ list provided and passed. Key milestone is always when we move from the development stage to validating in the market, meaning that key CTQs were confirmed, tested and agreed between us and our partner. Then we can move to the next step and repeat trialling material to confirm process runnability and create sufficient confidence with multiple batches of the material. 

As explained, through our modular approach of combining adhesive, carrier and liner to have a product that meets the customer’s needs, leveraging different technologies delivered the electrical safety that is required to have a safe vehicle that meets international safety requirements. This product combined a newly formulated flame-retardant coating with a flame-retardant PET film coming from Avery Dennison Hanita. Our wide technology platform, shared across various Avery Dennison business units within Materials Group, helped to create the appropriate solution.

The challenge

The second OEM had been working on their first dedicated in-house platform for several vehicles in their range. ‘Platform’ refers to the underpinnings that are shared across several car models – the wheelbase and track, key dimensions, and key components like battery pack and energy modules – of modern EVs.

Specifically, they needed to have good electrical insulation tapes to prevent arcing between the busbars and the aluminium module containing them.

Requirements as a function of both bulk and surface dielectric properties included: 

• a need for electrical insulation; 

• a very high thermal conductivity, which was appropriate for a gap filler adhesive or thick coatings, but not for thin PSA self-adhesive films; 

• a request that the electrical insulation should meet UL94 V0. 

The solution

We started working on the insulation requirements. Once the specifics had been defined – the breakdown voltage and tracking resistance, the peel strength on the aluminium substrate and the burn behaviour – we proposed that a recently developed product was the right solution to resolve the issue. It combines a flame-retardant adhesive with a flame-retardant PET film coming from one of our business units; Avery Dennison Hanita. 

This specialist division has serviced the label – as well as print, appliance and glazing  – industries with pioneering developments in film and laminates for more than three decades, adding value through thin coatings on polymer films. 

The OEM requirements included a very high thermal conductivity, which was appropriate for a gap filler adhesive or thick coatings, but not for thin PSA self-adhesive films. As these adhesive dielectric films are very thin and the contact area correspondingly large, the thermal resistivity is the more important measure. We illustrated how a thin film can present a lower barrier to thermal energy flow than thick materials, even if they have higher thermal conductivities.

There was also a request that the electrical insulation should meet UL94 V0; explanation of how UL94 burn behaviour tests are made, interpreting the results and the use of the UL 94 VTM test method for thinner films helped to define a more appropriate burn behaviour target.

We are currently in the implementation phase and are working with the supply chain to have the first prototypes supplied; the first samples have been provided, for prototyping, vehicle testing and the first manufacturing trials  and we anticipate the first production samples to be produced on production tooling. 

The benefits

Prototypes for the OEM’s platform were made with our product for component and bench testing. After successful conclusion, some of the designs were revised and a few new requirements were added. The first prototypes were laser cut using our network with tape converters. This gave very clean and accurate parts that were then used by the OEM for module testing, and were built into a few prototypes for early vehicle evaluations. 

Further design changes were made until a final design was agreed. We then commissioned tooling to provide the samples to the producer, who was now responsible for integrating the electrical insulation with the prototypes. Through our expertise, they were able to fine tune the specification to describe what was needed to provide the required electrical safety. This yielded a functional product that could be realised at the cost targets the engineers were given. 

In the end, ours was one of two solutions approved (it is very rare that OEMs will only approve one solution, as this can risk the stability of the supply chain when there are no back-up options). As a result, we’ve gained a much deeper understanding of the needs of electrical insulating film. The coated film we used was actually developed for flame retardant labels, so it was gratifying to see how it also delivered on features that were not considered in its original design, especially the strong electrical tracking resistance performance.

Cohesion within business units

We work together in the Materials Group on functional coatings, adhesives and films, to offer a wide range of technologies and core capabilities. We leverage expertise and keep unique formulations accessible for all of our business units. That allows our client to use such solutions in both worlds enjoying similar compliance standards. 

In addition, as all departments within Avery Dennison have to check and comply with everything from quality standards and compliance to sustainability, it makes the client all the more confident – as we consider all aspects of the viability and compliance of the solution, the customer can focus on implementation.

With the knowledge gained, we are supporting a number of suppliers producing thermal management components for EVB where similar requirements are seen. At the same time, working with electrostatic discharging (ESD) materials opened up new opportunities in fields we were not yet considering. ESD features can be added to materials that can be used in environments with high risk of explosion. Our recent product launch confirms that. 

Stick with Avery Dennison: we’ve got you covered

As the pioneer in the pressure-sensitive industry, our expertise and global scale enable us to deliver innovative, sustainable and intelligent solutions to the automotive industry. We combine decades of innovation with deep knowledge of both regulatory and legal requirements. We know about the real-world conditions in which our PSAs, coatings and films must perform, and the technical challenges they have to meet. 

Find out how Avery Dennison can help you achieve your EVB production objective.