Rogers Corporation ProCell™ PCL-800 EV Flexible aluminum foil backed with a glass cloth
- Product Name: Rogers Corporation ProCell™ PCL-800 EV Flexible aluminum foil backed with a glass cloth
- Factroy Site: Yinchuan, Ningxia, China
- Price Inquiry: sales8@ascent-chem.com
- Manufacturer: Ascent Petrochem Holdings Co., Limited
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- Rogers Corporation ProCell™ PCL-800 EV Flexible aluminum foil backed with a glass cloth is typically used in formulations when compression force and operating temperature must be controlled within specific ranges.
| HS Code | 967831 |
| Manufacturer | Rogers Corporation |
| Product Name | ProCell PCL-800 EV |
| Product Type | Phase change thermal interface material |
| Backing | Aluminum foil with glass cloth |
| Flexibility | Flexible |
| Color | Gray |
| Thickness | 0.20 mm |
| Thermal Conductivity | 0.8 W/m·K |
| Thermal Impedance | 0.25 °C-in²/W |
| Phase Change Temperature | 45°C |
| Operating Temperature Range | -40°C to 125°C |
| Density | 1.8 g/cm³ |
| Volume Resistivity | 1 x 10^13 Ω·cm |
| Dielectric Strength | 10 kV/mm |
| Flammability Rating | UL94 V-0 |
| Standard Width | 300 mm |
| Standard Length | 50 m |
As an accredited Rogers Corporation ProCell™ PCL-800 EV Flexible aluminum foil backed with a glass cloth factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | One roll per carton, sealed in moisture-barrier packaging, clearly labeled with Rogers ProCell™ PCL-800 EV name, lot, and safety information. |
| Container Loading (20′ FCL) | 20′ FCL loading: Rogers ProCell™ PCL-800 EV flexible aluminum foil with glass cloth backing, securely palletized and braced for transport. |
| Shipping | Rogers Corporation ProCell™ PCL-800 EV, a flexible aluminum foil backed with glass cloth, is typically shipped as a non-hazardous, non-regulated solid article. Use clean, dry, damage-free packaging as general cargo. No UN number, hazard class, or packing group usually applies. Confirm classification against the current SDS and applicable transport regulations. |
| Storage | Store Rogers Corporation ProCell™ PCL-800 EV Flexible aluminum foil backed with glass cloth in a cool, dry, well-ventilated area, sealed in original packaging. Keep away from moisture, dust, direct sunlight, heat, ignition sources, and strong oxidizers. Protect from mechanical damage, sharp bends, and crushing. Ideal conditions: 10–30 °C and below 75% RH. Follow manufacturer SDS/label for shelf life. |
| Shelf Life | Shelf life is 12 months from date of manufacture when stored in original packaging at 23°C and 50% relative humidity. |
Rogers Corporation ProCell™ PCL-800 EV is specified in engine compartment harness routing where radiant heat from exhaust manifold shielding and mechanical abrasion from bracket edges operate concurrently. The aluminum foil side is oriented toward the radiant source to reduce incident heat flux by reflection, while the woven glass cloth side is placed against the wire bundle to distribute clamp load and prevent cut-through into crosslinked polyethylene wire insulation. In production, a 50 mm roll is spiral-wrapped with a minimum 50% overlap, which places two foil layers across the bundle circumference and eliminates direct line-of-sight gaps at the seam. Tension is held at the lowest stable setting on a pneumatic wrapping head, typically between 4 N and 8 N per 25 mm width, because higher tension displaces the glass cloth weave and creates wrinkles that reduce reflectivity. Incoming roll inspection records total thickness, mass per unit area, and foil-to-cloth adhesion. If selvage distortion exceeds 2 mm per 300 mm width, wrap-head tension is reduced because edge distortion causes the roll to drift on the traversing guide. The finished harness is fixed with high-temperature polyester or aramid cable ties at 200 mm intervals. Long-term heat ageing is evaluated under ISO 6722-1:2011 Class C conditions at 125 °C for 3 000 h, followed by cold impact at −40 °C. The terminal component is an engine harness segment rated for continuous exposure near turbocharger and exhaust gas recirculation hardware, where surface temperatures do not exceed 150 °C. Silicone-coated glass cloth variants are preferred when diesel engine vibration exceeds 20 Hz at 2 g root mean square because the coating suppresses fiber-to-fiber fretting that generates glass dust.
What Determines Shielding Integrity at Foil Overlap Seams?
Shielded enclosure seams fail when a discontinuous conductive path allows slot-antenna radiation from the seam aperture. PCL-800 EV is used as a low-profile seam barrier on cabinets where the aluminum foil provides a reflective and conductive outer surface and the glass cloth prevents buckling during installation. The critical process variable is overlap contact resistance, not bulk conductivity of the foil. Enclosure fitters abrade the mating aluminum surfaces with a nonwoven pad, clean with 70/30 isopropyl alcohol/water, and apply the laminate at 20 °C to 30 °C. A minimum 6 mm overlap is maintained on straight seams; corner treatments require a 25 mm double-layer patch because bending stress at the fold lifts the foil at radii below 3 mm. Cut edges are knurled over 2 mm to prevent exposed glass fibers from protruding into the seam gap. After application, a silicone roller with Shore A durometer 60 is passed over the seam at 10–15 mm/s to expel trapped air. Shielding effectiveness of the finished cabinet is tested in accordance with IEEE 299-2006 from 100 kHz to 1 GHz. Bonding of the aluminum layer across the seam is confirmed by DC resistance below 25 mΩ over a 50 mm seam length using a four-wire milliohm meter. The laminate installed in CE-marked equipment must satisfy RoHS Directive 2011/65/EU for lead, mercury, cadmium, and hexavalent chromium limits. Published data for this specific laminate in a fully conductive pressure-sensitive adhesive configuration is limited; when the glass cloth side carries a non-conductive silicone adhesive, through-adhesive conductivity is absent and the seam must rely on exposed-foil overlap contact.
Aircraft thermal/acoustic insulation blankets use the PCL-800 EV laminate as an external covering layer. The foil functions as a vapor retarder and radiant barrier, while the glass cloth supplies stitch holding and trauma resistance during installation in fuselage frames. Blankets are cut with 10 mm folded edge allowances on a tensioned cutting table, covered over mineral wool or polyimide foam filler, and closed with outward-facing foil seams. Needle punching is avoided because puncture holes compromise the vapor barrier; seams are instead secured with foil tape or mechanically clamped with polyetheretherketone fasteners. Flame exposure of the final blanket assembly is governed by 14 CFR 25.853(a) and 14 CFR 25.856 for thermal/acoustic insulation in transport category aircraft. The burn length and afterflame time are recorded on the assembled blanket, not on the facing material alone. Condensate trapped between the foil and polyimide film reduces insulation efficiency; drain holes of 3 mm diameter are punched only in designated low-point zones. The terminal product is a fuselage blanket with a foil-facing surface on the side opposite the fuselage skin, installed with 100 mm to 150 mm compression around stringers to prevent billowing under cabin pressure cycles.
| Environment | Standard designation | Test condition | Governing parameter |
|---|---|---|---|
| Engine harness | ISO 6722-1:2011 | 125 °C long-term ageing, 3 000 h | No cracking after cold impact at −40 °C |
| Shielded enclosure | IEEE 299-2006 | 100 kHz–1 GHz | Seam DC resistance <25 mΩ per 50 mm |
| Aircraft thermal blanket | 14 CFR 25.853(a) / 25.856 | Vertical burner, 12 s flame | Burn length and afterflame on final blanket |
| Furnace expansion joint | ASTM E84-23a | Surface burning test | Flame spread index ≤25, smoke developed index ≤450 |
| Marine exhaust lagging | IMO FTP Code 2010 Part 5 | Surface flammability | Low flame spread on faced insulation assembly |
| Paint bake oven seal | DIN 75201 | Fogging reflectometric, 3 h at 100 °C | Condensate value class on final adhesive |
| Battery propagation | GB 38031-2020 | Module thermal propagation test | No external fire per vehicle-level criteria |
Furnace Duct Expansion Joint Covers and Surface Burn Characteristics
Industrial furnace ducts operating between 200 °C and 350 °C use PCL-800 EV as the outer membrane of preformed mineral wool expansion joints. The aluminum layer reflects radiant energy away from the joint cavity, while the glass cloth resists tearing at bolt-hole locations and accommodates compressive set when the bellows flexes. In fabrication, the laminate is wrapped over a 25 mm thick ceramic fiber blanket and bonded with a sodium silicate adhesive applied at 200 g/m² wet film using a serrated trowel to avoid dry bands. Overlapping edges are staggered by 100 mm from the blanket butt joints so that dimensional movement does not open a direct thermal path. The finished cover is clamped with 316L stainless steel bands at 200 mm centers; punching through the laminate is limited to mechanical fastener locations sealed with high-temperature silicone. Assembly-level flame spread is tested under ASTM E84-23a; a Class A assembly requires a flame spread index no greater than 25 and smoke developed index no greater than 450. The glass cloth must be specified without polyvinyl chloride sizing because combustion gases from vinyl sizing raise smoke density under forced-draft conditions.
When Oil Mist and Deck Washdown Coexist on Marine Exhaust Lagging
Marine exhaust piping in machinery spaces exposes insulation facing to a dual attack: intermittent oil mist lowers surface tension and allows capillary wetting of glass cloth, while low-pressure deck washdown drives salt water into cut edges. PCL-800 EV is specified for removable insulation pads on exhaust pipes where the foil side faces outward and the glass cloth side contacts the insulation. Edges are folded back 12 mm and double-stitched with aramid thread; stitching is then encapsulated with one-part oxime silicone sealant to prevent wicking along the thread line. Pad attachment uses 316 stainless steel compression springs at 300 mm intervals to maintain uneven contact pressure without puncturing the foil. The finished pads are evaluated for surface flammability in accordance with IMO FTP Code 2010 Part 5 when installed as part of a lagging system. The operational boundary is the continuous surface temperature of the underlying insulation: above 220 °C, silicone sealants at the cut edges become brittle and crack under hull vibration, which opens the glass cloth to oil ingress. The terminal product is a removable insulation pad for dry exhaust risers and charge-air coolers, not for wet exhaust bellows where direct water impingement exceeds 0.5 bar.
Paint bake oven door seals impose a longer thermal soak on the pressure-sensitive adhesive than on the aluminum facing. PCL-800 EV is used as a facing layer over closed-cell silicone foam door gaskets where the radiant load from infrared emitters reaches 180 °C to 230 °C for 20 min per cure cycle. The aluminum foil reduces heat absorption into the foam core, while the glass cloth prevents puncture from body hangers and tooling carts. Application on a horizontal door flange requires abrading the silicone foam with a primer-less adhesion promoter, then laminating the cloth side with a platinum-cured silicone pressure-sensitive adhesive. Overlap is set at 25 mm on flat flanges and 50 mm on curved corners. The adhesive is allowed to crosslink for 72 h at 23 °C and 50% relative humidity before first heat cycle; heating earlier produces adhesive outgassing that can deposit as fog on class-A painted substrates. Fogging is measured on the final gasket assembly according to DIN 75201 with a 3 h at 100 °C beaker temperature to ensure no volatile fraction exceeds the vehicle interior condensate limit. The glass cloth sizing and pressure-sensitive adhesive are selected to keep total bromine and chlorine content below 900 ppm when tested by EN 14582, because oven recirculation can carry halogen acids to painted substrates. The terminal part is a door seal strip for high-temperature paint bake ovens where solvent resistance to methyl isobutyl ketone is a supplementary plant-specification requirement.
Battery Module Thermal Propagation Barriers Operate Under a Different Failure Sequence
Lithium-ion battery modules use PCL-800 EV as a thin passive reflector between prismatic cells and adjacent compression pads. During a single-cell thermal runaway event, the aluminum foil faces the cell wall to reflect a portion of the incident radiative energy, while the glass cloth side insulates the compression pad and reduces char formation on polyurethane foam. The laminate is die-cut to the cell side profile with a 2 mm clearance around venting ports, because covering the cell vent can redirect gas and create an internal explosion hazard. Sheets are placed without adhesive in the first assembly stage; after stacking, the module compression plate is closed to a target thickness corresponding to 20% to 30% compression of the polyurethane pad. The material contributes to propagation resistance only as part of the total stack; it is not a structural firewall. Module-level verification is conducted under GB 38031-2020 for thermal propagation and under UN 38.3 for transport, but published data for this specific laminate in a full module configuration is limited and test outcomes depend on cell chemistry, venting direction, and compression force. The operational boundary is the foil melting point: continuous exposure beyond 600 °C in an oxidizing environment causes aluminum foil to lose mechanical continuity, leaving the glass cloth as the remaining barrier. The terminal product is a prismatic module with alternating cell, PCL-800 EV sheet, compression pad, and liquid-cooled cold plate.
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- Rogers Corporation ProCell™ PCL-800 EV Flexible aluminum foil backed with a glass cloth is manufactured under an ISO 9001 quality system and complies with relevant regulatory requirements.
- COA, SDS/MSDS, and related certificates are available upon request. For certificate requests or inquiries, contact: sales8@ascent-chem.com.
Rogers Corporation ProCell™ PCL-800 EV is a flexible aluminum foil backed with a glass cloth, supplied as a laminated composite for electrified vehicle battery pack applications. The material stack consists of a thin aluminum foil face and a woven glass cloth backing; the foil layer provides a low-emissivity reflective surface and the glass cloth contributes tear propagation resistance and dielectric separation. The PCL-800 series modifier is not interchangeable with other numerical ProCell grades because compression force deflection, thickness tolerance, and flame performance may differ. Current revision-controlled Rogers Corporation data sheets should be consulted for nominal foil thickness, foil alloy, glass fabric areal weight, and adhesive chemistry; published data for this specific configuration are limited. The product is supplied in roll or sheet form depending on converter requirements, and the roll width should be specified to match flat-bed or rotary die-cutting equipment.
Aluminum foil thickness in this composite class typically falls between 0.018 mm and 0.15 mm; glass cloth areal weight is generally in the range of 80 g/m² to 250 g/m². The woven backing is commonly a plain-weave E-glass fabric with a silane-compatible finish. The adhesive interlayer, when present, is subject to shear stress at die-cut edges and should be characterized by ASTM D1000 peel adhesion. Standard roll widths for converter equipment are typically 610 mm or 914 mm, but custom slitting may be available. The composite is not intended for continuous flexure beyond the fatigue limits of the aluminum foil; repeated bend radii below 10 mm can initiate foil cracking at the glass cloth intersections. This restriction is relevant in prismatic cell compression pads where the material may be compressed from 0.5 mm to 3.0 mm over vehicle service life.
How Are the Aluminum Foil and Glass Cloth Faces Characterized by Standard Test Methods?
Tensile strength and elongation of the laminate are evaluated according to ASTM D3759 for pressure-sensitive tape configurations or ASTM D882 for unsupported thin films. Thickness is measured with a dead-weight micrometer per ASTM D374. Dielectric breakdown voltage is recorded per ASTM D149 using perpendicular electrodes in air; surface resistivity is measured per ASTM D257. The glass cloth tear resistance is evaluated by ASTM D1424 or ASTM D624 depending on laminate construction. Flammability is assessed to UL 94; battery enclosure specifications may additionally require smoke density per ISO 5659-2 and toxicity limits under SAE J369. For applications requiring low-outgassing behavior, ASTM E595 is the relevant test method, although acceptance limits are OEM-specific and not governed by the material data sheet alone.
Within a cell-to-pack or module-to-pack architecture, the laminated foil/glass cloth is inserted between the cell stack and the compression pad or between the pad and the module housing. When the glass cloth side faces the cell can, point loads from weld tabs and can corners are distributed across the woven reinforcement; the aluminum foil side faces the compression plane to reduce radiant heat transfer and provide a low-friction surface against the pad. The composite is fabricated by flat-bed die-cutting, kiss-cutting, or CNC routing. Burr formation on the aluminum edge is a known failure mode when blade clearance exceeds 0.01 mm; rotary die stations with hardened tool steel reduce foil rollover. If a matched metal die is used, the die pressure should be set to limit foil extrusion into the clearance gap. Laser processing with a 10.6 µm CO&sub2; source can char the glass cloth if pulse overlap exceeds 70%; parameter validation is required before production release. Incoming glass cloth lot-to-lot variation in residual sizing can shift surface energy and alter foil adhesion; a dyne pen check at 38 mN/m or higher is recommended before lamination.
On production-scale lines, edge debris from die-cut aluminum foil has caused downstream contamination in ultrasonic welding stations. Slivers released from the foil edge can settle in cell terminal gaps and create latent short circuits. Therefore, post-cutting dry-web cleaning or tack rolls are standard for high-volume EV battery pack lines. The glass cloth backing reduces sliver generation compared with unsupported foil, but the die condition and blade sharpness still determine the final edge quality.
Performance Boundaries Against Unbacked Foil, Silicone Foam Facings, and Polyimide Films
Compared with an unsupported aluminum foil of the same thickness, the glass cloth-backed composite exhibits higher puncture resistance and edge tear strength, but the bending stiffness increases and conformability around radii below 5 mm is reduced. The woven glass cloth also increases the dielectric path length compared with a bare foil, although the exact dielectric strength depends on resin finish and moisture absorption. Against silicone foam facings, the aluminum/glass cloth stack provides a lower coefficient of friction on dry metal surfaces and better resistance to fretting wear, but it does not contribute bulk compression set recovery unless a cellular core is laminated beneath it. Relative to polyimide film tapes, the glass cloth backing tolerates higher continuous temperature excursion but has greater thickness and lower elongation before break. Polyimide films offer higher dielectric strength per unit thickness, while the glass cloth offers better fiber tear resistance under screw or bolt compression. Where electrical isolation is required, the aluminum foil side must not be placed against exposed busbars or cell terminals without an additional insulating layer.
Within the Rogers portfolio, the PCL-800 EV foil/glass cloth configuration differs from unfaced PORON 4701-30 cellular urethane and BISCO BF-1000 silicone because the facing carries electrical and thermal interface functions rather than bulk compression stress relaxation. Unfaced PORON and BISCO products rely on polymer matrix viscoelasticity; the foil/glass cloth laminate relies on the woven reinforcement for tear strength. Substitution of another ProCell grade without revalidating the facing and backing stack is not recommended. The PCL-800 EV designation should be ordered as a complete material system because the facing option is not a field-applied conversion.
When the Foil Face Is Oriented Against a Cell Can or Busbar
If the aluminum foil side is placed against a cell can or busbar, the surface resistivity measured per ASTM D257 becomes a functional electrical parameter. A bare aluminum foil face is conductive and can form a galvanic couple with copper or nickel-plated steel under electrolyte exposure; an additional insulating layer or edge seal is required. The glass cloth side may provide dielectric separation, but the breakdown voltage is limited by the glass fabric thickness and finish. In validation, the laminate is aged at 85 °C and 85% relative humidity for 1000 h and then subjected to dielectric withstand per ASTM D149 to screen for moisture-driven breakdown. This test condition is common in automotive electrification durability programs, though published data for this specific configuration are limited.
Thermal Aging, Peel Adhesion, and Dielectric Withstand in Battery Pack Validation
Production-scale converters typically monitor thickness profile, basis weight, peel adhesion, and flame rating for each incoming lot. Adhesion failure between the foil and glass cloth is screened by a 180° peel test per ASTM D1000 after thermal aging at 85 °C for 168 h; a loss of more than 30% of initial peel strength is a common rejection limit for EV battery pack suppliers. Batch release documentation should include a revision-specific certificate of analysis because the glass cloth finish and foil temper are not visible from surface appearance. The product should be stored flat at 20 °C to 25 °C and 40% to 60% relative humidity; moisture absorbed by the glass cloth can increase dielectric loss and cause blisters during lamination. Without a revision-specific data sheet, downselecting a replacement material is not recommended because the foil alloy, glass fabric weight, and adhesive type determine the processing window and end-use compliance status.
Evaluating Batch Release Data Against Generic Foil/Glass Cloth Laminates
Generic foil/glass cloth laminates may show similar visual structure but differ in glass finish, foil temper, and adhesive chemistry. A comparative incoming inspection should include ASTM D1000 peel adhesion, ASTM D3759 tensile strength, ASTM D149 dielectric breakdown, and UL 94 flammability. The PCL-800 EV data sheet values should be used as the acceptance baseline, not the supplier’s generic material class values. If the generic material passes these tests, a full battery pack thermal cycling validation is still required because interfacial adhesion can shift after repeated compression and temperature excursions.
Do Not Use the Foil Side as a Primary Insulation Barrier
The aluminum foil face is not an insulation layer in high-voltage battery packs. In pack designs where the busbar or cell terminal is exposed, the foil side must be isolated with a polyester film, polyimide film, or coated glass cloth. If the product is used as a grounding plane, the grounding path should be designed with dedicated conductive adhesive or mechanical fastening; edge contact alone is not reliable after thermal cycling. Insulation testing of the assembled part should follow IEC 60664-1 clearance and creepage requirements or the OEM-specific high-potential test procedure. Published data for this specific configuration are limited, so the dielectric rating of the complete assembly should be verified on the final part geometry rather than on flat sheet alone.
Flat-bed die-cutting of this composite on a 200 kN hydraulic press with a steel rule die has shown that edge burrs can be reduced by using a kiss-cut depth set at 0.05 mm below the foil thickness and a final cut through the glass cloth with a separate die. Laser systems configured with a 9.3 µm wavelength source generate less glass char than 10.6 µm sources, but cutting speed must be reduced to limit foil melting. These observations are based on general converting practice for foil/glass cloth laminates and should be confirmed with the product data sheet and process capability trials.
Published data for this specific configuration are limited; therefore, the immediate engineering decision for design release should be made from the current Rogers Corporation ProCell PCL-800 EV data sheet and the OEM material approval matrix, not from generic material class values.
