Batteries, especially lithium batteries, have high sensitivity in storage. This topic also poses significant risks during transportation and warehousing. Batteries are usually exposed to various dangers: physical damage (impact, scratches, pressure) can lead to short circuits or moisture infiltration into the cells, which in the worst case can cause “thermal runaway” or fires. Another challenge is complying with hazardous materials transportation regulations: lithium batteries are classified as class 9 goods (UN), and their packaging must pass stringent standards such as UN tests. Furthermore, temperature fluctuations during transportation (extreme heat or cold) can reduce performance or pose safety risks.
Supra Polymer Solution
To manage these challenges integratively, precise film combinations can be used in the battery packaging design: PET films serve as internal separators in the structure of battery cells (such as in Li-ion), while PP films (cast/CPP) can play a role in multilayer structures to separate and isolate cells. In pouch packaging (battery pouch cover), multilayer films with a PET/aluminum/PE layer can be utilized to provide high protection against gas infiltration, moisture, and thermal shock. In the secondary protective layer on battery units, LDPE films can be used, which have good flexibility and prevent scratches or surface impacts.
| PET films | used as separators in lithium-ion batteries |
| PP films (cast/CPP) | also battery separators in multilayer structures |
| Multilayer barrier films (PET/Alu/PE) | pouch packaging for Li-ion batteries |
| LDPE films | secondary protective layers for battery units |
| Pallet stretch wrap (LLDPE) | palletizing battery packs |
| PE shrink films | bundling battery cartons |
| Recyclable PET shrink | multipack batteries, small electronics accessories |
| Bubble wrap (LDPE blends) | cushioning heavy battery modules during transport |
Features
High Electrical Insulation
Films like PET and PP, used as separators in batteries, must have very high electrical resistance to prevent short circuits between the positive and negative electrodes. Polymer separators with appropriate porosity allow ions to move while maintaining physical insulation between cells.
Mechanical Resistance
Separators and protective layers must have sufficient strength to withstand mechanical pressure, impact, vibration, or tension during production or transportation processes. For example, separators must have high tear strength and puncture resistance.
Thermal Stability
Layers such as PP or multilayer films must be stable at high temperatures and have safety performance during hazardous conditions (like excessive heat). In some designs, when the temperature rises, parts of the separator may melt and cut off the current to prevent the escalation of thermal incidents.
Shock Absorption and Physical Protection
Flexible layers like LDPE or LDPE blends in bubble wrap are capable of absorbing shocks, vibrations, or physical impacts, preventing surface damage (scratches, bends) to modules or battery cells.
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