In this paper, we explore trends in future electric vehicle (EV) battery design with a focus on the cell-to-pack configuration and how Thermally Conductive Adhesives (TCAs) play an important multi-function rol. With the rapid growth and adoption of electric vehicles, OEMs and battery manufacturers are turning to technology t. Thermally Conductive Adhesives (TCAs) are key Thermal Interface Material (TIMs) used in Cell-to-Pack configurations, providing structural bonding and thermal conductivity. In this configuration TCAs are dispensed on th. EV manufacturers are ambitiously striving to build lighter, less complex, less costly electric vehicles with battery systems that are more compact, have longer ranges and higher energy densities. These goals bring new and more de. TIMs are designed to improve thermal conductivity and reduce contact resistance by filling air gaps, allowing for faster and more eficient heat dissipation from battery cells to the cooling system. TIMs help reduce temperature gradients and hotspots within the battery pack, minimizing the risks of thermal stress and thermal runaway, a serious safety hazard that can cause battery fires.
[PDF Version]Courtesy of Dupont. Some adhesives for battery assembly serve a multifunctional role, providing structural joining, thermal management, and support for dielectric isolation. Adhesives in this class offer thermal management and medium strength that supports the stiffness and mechanical performance of the battery pack.
Dupont's BETAMATE (5) and BETAFORCE (7) are part of a broad portfolio of adhesives for numerous EV applications. The next generation of EV batteries is witnessing the emergence of cell-to-pack designs. These designs integrate battery cells into the pack using thermal structural adhesives.
Advanced adhesives and sealants like those from DuPont can help advance sustainability. An essential contribution of adhesives to EV battery design is that they allow for greater simplicity. For example, adhesives help reduce or eliminate mechanical fasteners, reducing battery complexity.
For this reason, thermal adhesives are used at several locations in battery modules, such as between individual cells, or between cells and cooling plates. Structural adhesives are used in EV battery packs to create bonds that can withstand various environmental conditions and mechanical loads.
Battery adhesives come under various forms, such as liquids, pastes, gels, tapes, and pads. The distinct types of adhesives offer different benefits: Acrylic-based adhesives are known for their ability to bond a broad range of raw metals, composites, and thermoplastics.
Functional materials such as debondable structural adhesives and debondable thermally conductive adhesives will enable OEMs and battery manufacturers to include debond-on-demand solutions into EV batteries, thereby extending the maximum lifetime of batteries and easing the dismantling process for EOL applications.
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