Advancements in EV Battery Technology: Enhancing Innovation and Efficiency

Driving EV Battery Innovation and Efficiency
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By Karl Vadaszffy
July 1, 2025
6 Mins Read

In a rapidly evolving industry, thermal management, cushioning, and sealing technologies are transforming the design, assembly, and protection of battery packs. With the increasing complexity of battery pack designs due to the advancements in electric vehicles (EVs) and hybrids, 3M, a science-based innovator, is at the forefront of creating barrier materials, cushioning materials, and sealants. Their extensive portfolio addresses critical challenges related to thermal management, battery pack assembly, cost reduction, and manufacturing efficiency.

One of the most significant concerns in lithium-ion battery systems is thermal runaway. To tackle this issue, 3M offers the 3M Thermal Runaway Barrier 600/700 Series. These products consist of compressible, flame-resistant thermal insulation mats that can withstand temperatures up to 1,200°C while maintaining structural integrity even in extreme conditions. Anja Rohmann, an advanced application engineering specialist at 3M, explains, “The mats are made from non-classified fibers, providing good flame resistance, and are designed to slow down heat transfer between cells. Both series can be applied between cells to help minimize thermal transport at high temperatures.”

Maintaining consistent pressure within battery packs while absorbing mechanical stresses and vibrations is a key challenge during assembly. The 3M Cell Expansion Foam SJCEF, a flame-retardant microcellular polyurethane foam, addresses this need. Its self-tacky properties streamline operations by reducing process steps and assembly time. Rohmann adds, “It features a customizable compression plateau for consistent battery pressure and comes in various thicknesses, accommodating multiple battery designs without sacrificing performance—ideal for both EV and hybrid applications.”

Battery enclosures require sealing to prevent moisture ingress, protect internal components, and ensure future serviceability. The 3M Sealant SZ1000 for EV Enclosure Sealing is a two-part, cure-in-place foam sealant that meets these requirements, offering flame retardancy and excellent aging durability while being compatible with automated dispensing. Rohmann highlights its critical role in maintaining long-term battery pack integrity across varying environmental conditions.

According to Rohmann, product development in the battery sector is dynamic. OEMs constantly refine their designs to meet evolving performance, cost, and safety targets. She comments, “Customers develop and optimize their battery designs very dynamically in response to the industry’s constantly changing challenges. This can sometimes be very short-term. Our experience is crucial in anticipating certain material properties or incorporating them in advance.”

This rapid iteration cycle poses challenges for material suppliers, yet 3M remains agile without compromising on quality or reliability. Their innovation strategy relies on direct engineer-to-engineer collaboration, which they refer to as ‘bench-to-bench’ development. Rohmann elaborates, “Close collaboration with the OEM is crucial for successful development. Once key opportunities are identified, engineers can sit down and discuss technical challenges, allowing everyone to understand where the pain points lie—whether in the product concept or in integrating an innovative idea into the manufacturing process.”

When OEMs face challenges, they become 3M’s challenges. “A primary concern for OEMs is cost reduction,” Rohmann says, adding, “Reducing the cost of battery packs to make electric vehicles more affordable is a major challenge.” This involves optimizing manufacturing processes and material usage while balancing performance with costs. Additionally, as energy density increases, so does the heat generated, making efficient heat management essential for safety and performance. Rohmann points out that 3M is currently developing advanced materials with high thermal stability and low conductivity to tackle these challenges.

The industry has transitioned from early battery pack designs that utilized single-purpose materials to a focus on multi-purpose materials. Rohmann explains, “With increased emphasis on vehicle affordability and industrialization, OEMs seek solutions that not only meet application goals but can also be seamlessly integrated into their manufacturing processes.” She notes that OEMs are looking for material solutions that address various requirements unique to emerging chemistry and form factors in the market. For thermal runaway barriers, this means selected materials must maintain high thermal stability while also offering excellent elasticity and extended durability.

This delicate balance of properties requires a deep understanding of materials science and continuous feedback from real-world applications—something that 3M is uniquely positioned to provide. Furthermore, safety and environmental regulations are shaping product development. Rohmann states, “Regulations for EVs and thermal events aim to enhance safety, performance, and environmental compliance.” Environmental mandates, like the EU Battery Directive and End-of-Life Vehicle Directive, are influencing designs by promoting materials that facilitate disassembly and recycling. These considerations are integrated into the company’s R&D plans to ensure they remain prepared for the future.

While EV and hybrid battery packs encounter different challenges—such as energy density for EVs and integration with internal combustion engines for hybrids—many solutions can be shared or complement each other across platforms. Rohmann asserts, “Advancements in battery technology, thermal management, and control systems for one type can often be adapted for the other.” Improvements in manufacturing efficiency and cost reduction techniques can benefit both full EVs and hybrids.

This cross-pollination of ideas and technologies will lead to robust, flexible solutions capable of addressing the entire spectrum of EV requirements. “By tackling these challenges with innovative solutions and leveraging synergies between full EV and hybrid technologies, we can enhance the performance and competitiveness of both vehicle types,” Rohmann concludes.

[3M](https://www.3m.com)