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Battery Cell Bonding
Bonding cells together can insulate and protect electric vehicle (EV) and hybrid vehicle (HV) batteries from movement and vibration.
Bonding Solutions for Electric Vehicle Battery Cells
To provide insulation and protection against vibration and movement during the manufacturing process and throughout the life of the battery, cells within the battery pack or module need to be bonded together.
Depending on the battery design, cells also need to be bonded to a frame or cold plate. This helps dissipate thermal activity and keep contaminants out of the battery pack.
Bonding application sometimes varies by cell type.
- Cylindrical cells are bonded to a polycarbonate carrier with two component or UV-cure acrylics.
- In prismatic cells, adhesive is dispensed in between each cell
- In pouch cells, hot melt pressure sensitive adhesive (PSA) is used to bond cells together and to frames or a cold plate.
Cell to Carrier Bonding Stabilizes EV Batteries
In cell to pack bonding – also known as cell to carrier bonding – many cylindrical battery cells are fused onto a plastic carrier, keeping cells stationary at very short distances from each other. This allows the cells to maintain structural integrity while protecting them from vibration and movement during the welding process and life of the product.
For cell to pack applications, EV battery manufacturers often choose between two acrylic types:
- UV-cure acrylics that only dry when exposed to ultra violet light
- Two-part methyl methacrylate adhesives (MMAs) that fuse regardless of light level
Both have their unique benefits and challenges.
Whichever adhesive you select, automation plays a significant role in a successful cell to carrier bond. To achieve acceptable cycle times and a robust process, choose dispensing equipment that can handle the speed, repeatability, and precision required.
Discover Solutions for Cell Bonding Applications
These products are a representation of possible options for your finished system. Your solution is configured for your specific needs.
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Dispensing Systems
Dispense Valves
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Related Materials
Parker LORD Sipiol UV
Sipiol UV was developed specifically for electric vehicle (EV) battery applications. It cures in seconds with UV light, and is electrically insulative.
PPG CoraChar SE 4000
PPG CoraChar SE 4000 intumescent fire protective coating shields electric vehicle (EV) battery packs and electrical energy components from external fires and internal thermal runaway events.
Sika Sikagard-834
Sikagard 834 epoxy-based intumescent fire protection coating protects electric vehicle (EV) batteries from thermal events.
Tflex CR607
At 6.4 W/m-K thermal conductivity, Tflex™ CR607 is at the forefront of thermal performance for a two-part, cure in place dispensable gap filler.
VM 1802
LG Chem VM 1802, a two-component thermal material for EV Battery and Electronics heat transfer applications.
Liqui-Form 3500 (LF3500)
Henkel - BERGQUIST® LIQUI-FORM 3500 is a high conductivity gel thermal interface material designed for demanding applications that require a balance between dispensability and low component stress during assembly.
HB Fuller EV Protect 4006
EV Protect 4006 is a two-component flame retardant, low-density polyurethane foam designed for potting and encapsulation of cylindrical cells in EV battery modules.
HB Fuller EV Seal 500
Learn more about EV SEAL 500, an easy to apply, fast setting, and resealable gasket material used in automotive and EV battery applications.
LORD CoolTherm SC-1200
Since CoolTherm® SC 1200 thermally conductive silicone gap filler is highly abrasive, Parker LORD® asked Graco to find out how to dispense one million shots of the two component material without equipment failure.
LORD CoolTherm TC-2002
Parker Lord CoolTherm® TC-2002 adhesive is a two-component adhesive system designed for use in structural bonding applications which require thermal conductivity with high bond strength.
Dow SYLGARD 170
SYLGARD™ 170 Fast Cure Silicone Elastomer is a two-part general purpose encapsulant with low viscosity, good flow ability, and flame resistance that cures fast at room temperature.
Dow Dowsil EF-6525 RTV Low-Viscosity Silicone Foam
DOWSIL™ EF-6525 RTV Low Viscosity Silicone Foam is a two-component low-density liquid elastomer that cures into a foamed elastomer.
Choose Elite construction for applications of highly abrasive thermal interface materials (TIMs), silicones, urethanes, and epoxies. When your system configuration includes pumps and valves with Elite construction, you can expect to…
- dispense at least 50,000 gallons (200,000 liters) before noticing any wear on pump pistons and cylinders*
- get at least 10 times more equipment life, compared to standard systems*
How do we know? Read the research.
* Results may vary. Variables affecting component life include, but are not limited to, material chemistry/fillers, flow rate, cycle rate, maintenance diligence, and system pressure.
Contact an EV Battery Expert
We understand the complexity of battery designs, and how material application affects their manufacturability. We look forward to collaborating with you to improve your battery manufacturing processes.
