Die-Cut Battery Components for Thermal Runaway Protection Delay, isolate, or contain abnormal thermal events.
Whether you are designing a part to reduce cell-swelling-related failures, mechanical abuse events or electrical shorts or to stop propagation from one cell to the next, if the part can be fabricated from flexible material, JBC Technologies can make it. JBC converts high-performance materials into custom die-cut components that help reduce propagation risk, support electrical isolation, and protect critical battery pack structures.
PROTECT AGAINST THERMAL RUNAWAY WITH DIE-CUT COMPONENTS
From Specialty Materials to Functional Components
Using our vertically integrated converting capabilities, JBC combines specialty materials, each with its own performance attributes, into single, lightweight, economical, easily installable components with multiple end-use contributions. Parts can be supplied in formats that support manual placement, robotic pick-and-place, automated dispensing, or high-volume assembly.
These custom-converted parts serve three core functions:
INSULATE
Slow heat transfer and isolate cells, modules, and pack structures.
CONTAIN
Manage heat exposure to delay propagation and support thermal event containment.
PROTECT
Protect sensitive components from mechanical, thermal, and dielectric failure modes.
What is Die-Cut Thermal Runaway Protection?
Die-cut thermal-runaway protection components are custom-converted parts used between cells, modules, packs, busbars, covers, and other sensitive areas in and around a battery pack to help reduce propagation risk. Examples include:
- Cell-to-cell barriers
- Cell-to-module interfaces
- Module-to-pack interfaces
- Pack covers and lids
- Busbar insulation
- Electrical isolation pads
- Compression pads
- Vent path or flame exposure zones
- Sensitive electronics / BMS protection
- Enclosure seals and interfaces
Depending on the application, they can support propagation delay, containment, electrical isolation, and mechanical or compression management. What they don’t do is prevent thermal runaway on their own. They are part of a broader system designed to reduce risk, delay propagation, and protect surrounding structures.
Materials Used for Die-Cut Thermal Runaway Protection
In a demanding battery environment, materials rarely fall neatly into a single category. For example, high-performance solutions like EST™ compression papers do double duty: they provide the mechanical cushioning required to absorb cell swelling and vibration during normal operation, while simultaneously offering the extreme thermal barrier properties needed during a thermal event.
Even with these multi-functional materials, there is no “silver bullet” or catch-all material that does everything—which is where a specialized converter like JBC Technologies adds immense value. Custom die-cut multilayer laminates offer high functionality in a small footprint, helping boost battery lifespan and durability.
This table illustrates some of the many materials JBC Technologies converts for battery, energy storage, and other applications.
*Most of the converting/ JBC advantage points are applicable across all material types.
WHEN YOUR GOAL IS TO |
CONSIDER |
BENEFITS |
CONVERTING / JBC ADVANTAGE |
|---|---|---|---|
INSULATE: Slow heat transfer and isolate cells or pack structures |
|
High-temp insulators can reduce heat transfer between cells, modules, covers, and surrounding pack structures. |
|
CONTAIN: Manage, delay, or localize thermal events |
|
These materials support containment in different ways: intumescents can expand and form char under heat, while ceramic papers and flame-resistant barriers help resist flame, limit heat transfer, and provide physical separation. |
|
PROTECT: Support electrical isolation, compression, and mechanical durability |
|
Reduce short-circuit risk, isolate busbars or conductive surfaces, manage swelling and compression, cushion components, and improve mechanical reliability under vibration. |
|
On Demand Webinar
Watch our on-demand webinar. It's an engaging Q&A discussion, where our panel of experts covers a range of different performance materials that provide engineers with solutions to day-to-day operational challenges.
Key takeaways:
- Materials for Daily Performance: Discover solutions that optimize routine battery operations, maintain uniform thermal management, and enable faster charging, longer range, and a better driving experience.
- Materials for Thermal Isolation & Safety: Learn about specialized materials designed to block thermal propagation between cells, preventing runaway heat from cascading and protecting neighboring cells from mechanical wear caused by repeated expansion and contraction.
- Integrated Multi-Material Parts: Hear how converting experts like JBC Technologies can combine these distinct performance and safety materials into custom, single-SKU components—giving you full functionality without adding assembly complexity.
FAQs: Custom Converting for Thermal Runaway Protection Applications
Materials come from the manufacturer in large buns, rolls, or sheets. To function in a battery module or pack, they need to be transformed to fit the space and application requirements. Sometimes this can be done inline at the battery assembly plant, but more often than not, a flexible materials converter such as JBC Technologies will perform this function. Converting turns a high-performance material into a usable battery component.
Yes. Using our laminating equipment, JBC Technologies can combine multiple materials into multi-functional parts. These constructions can provide electrical isolation, heat spreading or insulation, mechanical cushioning, flame resistance, and environmental protection while reducing the need for separate layers.
Pressure-sensitive adhesives do more than attach a component to the battery pack. The right adhesive can support thin, low-profile bonding, add dielectric strength, improve flame-retardant performance, enable lamination of multiple materials, and simplify installation.
JBC combines material selection support, design for manufacturability assistance, prototyping, laminating, slitting, rotary die cutting, flatbed die cutting, digital cutting, and part presentation expertise to help turn advanced materials into production-ready battery components. The value is not just cutting a shape; it is the total solution that fits the battery application, assembly process, and production scale.
Die-cut battery components can be supplied as individual “through cut parts,” on rolls, sheets, liners, kiss-cut formats, tabbed parts, gapped formats, or custom packaging designed to improve handling, automation, and assembly speed.
Yes. Digital cutting and prototyping capabilities can support early fit, form, and function testing before moving into higher-volume die cutting.
Related Reading... Die Cutting, Thermal Management, and EVs
Custom Thermal Runaway Protection Components Why JBC Technologies
With vertically integrated converting capabilities and years of experience converting thermal management materials, JBC’s market advantage is built on the trifecta of engineering innovation, manufacturing excellence, and supply chain optimization.
Whether you need a single material with an adhesive backing or a complex multi-layer laminate die-cut to shape, we will deliver the high-quality results you need.
We do this through
-
Part Presentation
-
Automated Assembly
Contact us today to learn how we can help you achieve your goals.