Charged EVs | Enhancing EV battery packs with foams, adhesives and high-performance thermal supplies

Efficient thermal administration is among the most crucial points of EV battery pack design. Engineers should not solely guarantee environment friendly warmth dissipation throughout charging and discharging cycles but additionally preserve uniform temperature throughout all cells to optimize efficiency and lengthen battery life. This requires integrating superior supplies—corresponding to flame-retardant foams, adhesives, and hole fillers—that may concurrently management warmth movement, present structural reinforcement, and enhance general security.

To be taught extra about addressing these thermal challenges on the materials degree, Charged just lately chatted with Germaine Mariaselvaraj, Technical Service Supervisor at H.B. Fuller. Germaine defined how their EV Defend foam sequence addresses a core problem in EV battery design: stopping thermal runaway from propagating between cells. The froth acts as a fireplace?retardant barrier, serving to isolate a single failing cell in order that the remainder of the pack stays intact. Past simply security, it additionally delivers structural and vibration-resistance advantages, which many battery integrators depend on to satisfy sturdiness requirements with out including heavy metallic or plastic stiffeners.

H.B. Fuller’s first providing, EV Defend 4006, is a semi-structural foam that flows into cavities and expands to encapsulate elements. As market calls for shifted towards extra structural options, H.B. Fuller launched EV Defend 5006, 5008, and 5009—variations with elevated stiffness that permit for the discount or alternative of conventional structural components. The upshot: diminished half depend, decrease mass and a extra built-in pack structure that helps newer architectures like cell-to-pack or cell-to-chassis.

Past thermal administration, the froth contributes to noise, vibration and harshness (NVH) management and thermal insulation. Some clients depend on the froth to assist them cross vibration testing that they may not obtain with naked elements, and since the froth envelops the cells, it additionally mitigates temperature swings in excessive ambient situations. In chilly or sizzling environments, the froth moderates native temperatures, serving to cut back the affect on vary or battery efficiency.

Germaine additionally mentioned H.B. Fuller’s EV Bond 775, a reactive hot-melt adhesive that streamlines battery module meeting. By changing tape or multi-step adhesive processes, this reactive hot-melt allows quicker bonding of mica to lids, cells and cooling tubes. That accelerates cycle time, reduces dealing with, and cuts scrap or rework—all invaluable in high-volume battery manufacturing.

On the gap-filling and thermal interface entrance, H.B. Fuller’s EV Them 288 (a silicone-free MS polymer) competes with conventional silicone hole fillers. As a result of it’s silicone-free, it helps meet stricter OEM constraints on supplies within the manufacturing surroundings.

Study extra about H.B. Fuller’s battery pack supplies portfolio https://www.hbfuller.com/ev.