Thermal Isolation vs. Fire Protection: How to Layer an EV Thermal-Runaway Barrier Stack
The most common specification error in thermal-runaway protection is asking one material to be two materials.
Aerogel, Firewall Barrier Sheet, Mica, Glass-Fiber Paper, or Silicone Foam: Selecting an EV Thermal-Runaway Barrier
Thermal-runaway barrier selection starts with an uncomfortable truth: there is no single "fire material." There are materials that slow heat conduction, materials that survive flame and ejecta, materials that also…
Aramid Paper, Polyimide Film or PEEK? Choosing Traction-Motor Slot, Phase and Wedge Materials
A traction motor asks for insulation in four distinct places, and each place rewards a different converted material. The slot liner wants toughness to survive winding insertion.
Why Traction-Motor Insulation Fails: Insertion Tears, Hot Spots, Fast Switching Edges and Oil
Most traction-motor insulation failures are not exotic. They start in five familiar places: a liner nicked during winding insertion, a hot spot that outran the insulation system's class, a thin barrier sized for…
Contact Resistance and the Slot-Antenna Seam: The Two Quiet Failure Modes in EV Power Electronics
Two failure modes in EV power electronics share a personality: both are invisible on the bill of materials, both live at interfaces rather than in components, and both are fixed by pressure.
Graphite, Boron Nitride Silicone, or Gap Pad: Choosing a TIM for EV Power Modules
Thermal-interface selection for an inverter, onboard charger, or BMS is mostly a geometry-and-electricity question wearing a materials costume.
Closed-Cell Silicone, Solid Silicone, EPDM, or Butyl: Choosing an EV Pack-Closure Seal
The pack-closure seal is the outermost ring of the battery's defense: the gasket at the lid, cover, or service joint that keeps moisture, dust, and the corrosion they drive away from the high-voltage interior.
Pack-Lid Gasket Geometry and Pressure-Equalization Venting: Designing the Outermost Seal
Two quiet design topics decide whether a pack lid still seals in year ten, and neither is the material grade.
Static or Dynamic, IP67 or IP6K9K: The Two Decisions That Shape an EV Module Seal
Before any material is named, a module or frame seal is shaped by two upstream decisions.