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Thermal Resistance, Electrical Insulation Polycarbonate (PC) Boards For EV Battery

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Thermal Resistance, Electrical Insulation Polycarbonate (PC) Boards For EV Battery

Polycarbonate boards offer a unique combination of properties that make them suitable for a vast range of applications, from electronic components in NEVs to construction and safety equipment. The material's customizability in terms of physical properties and aesthetics further enhances its applicability, allowing engineers and designers to tailor the PC boards to meet specific requirements of their projects.




Customizability Options

Impact Resistance

Exceptionally high resistance to impact, significantly more than glass or acrylic.


Temperature Tolerance

Can withstand temperatures from -150°C to 135°C, making it suitable for harsh environments.

Formulations can be adjusted for enhanced heat resistance up to 140°C or more.

Optical Clarity

High transparency, making it ideal for applications requiring clear visibility.

Tinting and coloration options are available for different visibility requirements.

Flame Retardancy

Self-extinguishing and flame retardant; can be enhanced with flame retardant additives.

Flame retardant grades available to meet specific safety standards.

UV Resistance

Prone to UV degradation but can be coated or modified for improved UV resistance.

UV protective coatings or additives can be incorporated.

Chemical Resistance

Good resistance to acids and oils, but can be susceptible to solvents.

Special grades can offer improved resistance to chemicals and solvents.

Electrical Insulation

Excellent electrical insulator, suitable for various electrical and electronic applications.


Dimensional Stability

Maintains shape and form under stress and heat, critical for precision components.



Lighter than glass, contributing to weight reduction in designs.


Custom Shapes and Sizes

Can be easily molded into complex shapes and sizes, offering design flexibility.

Tailored molds based on application needs; can include embossing, texturing, etc.

Surface Finishing Options

Smooth surface can be easily printed on, coated, or treated for specific applications.

Options for anti-scratch, anti-fog, and anti-glare coatings.

Polycarbonate (PC) boards find a significant role in the new energy vehicle (NEV) sector, particularly in the context of electric vehicle (EV) battery systems. Their unique combination of strength, thermal resistance, electrical insulation, and lightweight properties make them an ideal choice for various applications within the battery pack and its management system.

Applications of PC Boards in NEV Batteries

1. Battery Cell Spacers and Holders:** PC boards are used to create spacers and holders within the battery pack. These components are crucial for maintaining the physical separation between individual battery cells, which helps in mitigating the risk of electrical shorts and thermal runaway.

2. Battery Enclosures:** The enclosures or casings that house the battery cells or modules are often made from PC due to its excellent impact resistance and durability. These enclosures protect the battery from physical damage while also offering a degree of thermal insulation.

3. Electronic Control Unit (ECU) Housings:** The ECU, which manages the battery management system (BMS), requires robust housings to protect sensitive electronics from mechanical stress, thermal fluctuations, and electromagnetic interference (EMI). PC boards, with their good electrical insulation and stability, are perfectly suited for this application.


4. Connectors and Insulation Panels:** PC is used to manufacture connectors and insulation panels within the battery pack. These components benefit from PC's electrical insulation properties, preventing unwanted electrical conduction and ensuring the safe operation of the battery system.

5. Cooling System Components:** Certain components of the battery's cooling system, such as ducts and fans, can be made from PC due to its thermal resistance and ability to operate in a wide range of temperatures. This is essential for maintaining optimal battery temperatures during operation.

Value Brought by PC Boards in NEV Batteries

1. Safety Enhancement:** By providing strong, durable, and electrically insulating materials for battery components, PC boards enhance the overall safety of NEV batteries, protecting against mechanical impact, thermal runaway, and electrical faults.

2. Performance Optimization:** The thermal and electrical insulation properties of PC contribute to the efficient operation of NEV batteries, ensuring that they perform optimally under various conditions.

3. Design Flexibility:** The ease of molding and customizing PC boards allows for innovative battery pack designs, accommodating complex shapes and configurations that optimize space and enhance the vehicle's performance.

4. Weight Reduction:** PC's lightweight nature contributes to the overall reduction of the vehicle's weight, improving efficiency and range, which are critical factors in the performance of NEVs.


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