These adhesives keep the cells firmly in place throughout the vehicle's lifespan. Adhesive technology plays a vital role in the assembly and performance of electric vehicle battery packs. From ensuring structural integrity to managing heat and enhancing safety, adhesives, and sealants contribute significantly to the success of EVs.
According to Billotto, these adhesive materials act as interfaces between the battery cells and the cooling plates, ensuring heat is efficiently dissipated during charging and discharging. These adhesives enhance battery longevity by helping keep the batteries within the optimal temperature range (typically 35-60°C).
Structural Adhesives used in EV batteries must withstand high mechanical loads, as well as exposure to temperature extremes, humidity, and other harsh environmental conditions. The following methodologies are used to test the performance: the weight of the battery or vehicle, or internal stresses generated by thermal expansion or contraction.
On top of the thermal conductivity the adhesive further needs to show a good structural strength paired with a high elongation at break to maintain the mechanical structure over the lifetime of a battery also under load (e.g. vibration).
The selection of adhesives and sealants depends on the desired strengths, service considerations and to a great extent on the manufacturing requirements. A wide spectrum of adhesive systems offers the industrial designer new technology options and thermal management solutions for high-voltage batteries.
Structural adhesives have been used in car body engineering for many years and contribute positively to crash performance. The transfer of this technology to battery cages is possible with shear strengths larger than 10 MPa. Apart from specifying the physical properties, many other considerations are necessary before selecting the adhesive.
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The upper gap filler fills in the large spaces or gaps between the lower sides of individual batteries and the gaps between the bottom of the batteries and the inside wall of the module housing; this serves to firmly adhere the batteries in place while providing a continuous, thermally conductive (TC) pathway through which heat can travel. Such ...
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From the material side, adhesives, sealants, gaskets, and thermal materials are extensively used in battery modules. Industrial Market Insight estimates that the average EV utilizes nearly 8 lbs of adhesives and sealants between the battery and motor; even hybrid electric vehicles use nearly 2 lbs of adhesive in just those two areas of the ...
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