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Bonding and thermal management of high-voltage batteries

Batteries are a very common form of energy storage, the integration of high voltage batteries into electric vehicles is quite complex. 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.

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Battery cage

Adhesive technology constitutes a good alternative to traditional metal construction – particularly when stress-free, non-deformable and dimensionally stable components must be produced. Structural adhesives have been used in car body engineering for many years and contribute positively to crash performance. Semi-structural adhesives with lower modulus are suitable for tolerances and lower crash relevance of the cage.

Battery lid

The individual requirements on the serviceability of the battery are decisive for selecting the cover seal. If frequent service is expected, the cover can be mechanically fastened with a foam or elastomer seal. If the battery is only rarely opened or not at all, adhesive are possible solutions.

Thermal management materials

Thermally conductive adhesives provide an alternative to soldering heat sinks to the battery bottom. Silicone-based gap fillers used for years in the electronics industry are now complemented by one- or two-component polyurethane gap fillers that partially contain less abrasive fillers that also protect the pumps and dispensing systems.

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