The development of vehicles powered by battery or hydrogen requires out-of-the-box thinking. The adoption of simulation-driven methodology is not only vital to the optimal usage of human resources and materials, but also the most viable solution to innovation. The consolidation of vehicle platforms by vehicle manufacturers demands a modular approach for electric motor and battery pack design, which in itself lends to shared technology across vehicle platforms and manufacturers.

While significant resources are allocated to develop new battery technologies, vehicle manufacturers are looking into alternative fuel sources such as hydrogen due to stringent timelines to eliminate the sales of internal combustion engine (ICE) based vehicles. Fuel cell electric vehicles (FCEVs) operating with green hydrogen technology are a promising alternative to battery electric vehicles (BEVs). Fuel cells are more suitable for large vehicles such as trucks and trains considering the challenging battery size requirements for such large vehicles. In addition, they require less expensive commodities while tending towards zero emission, zero waste and no grid impact.

In this webinar, we will share a simulation driven methodology that can be adopted at any stage of propulsion system development for both BEVs and FCEVs with a robust, industry validated connected process. This includes leveraging pre-packaged workflows that apply to electric vehicles such as inverters and electric drives, as well as to bipolar plates and gas diffusion layers in hydrogen fuel cells. This highly scalable, customizable process will empower propulsion system engineering teams to develop solutions that are both suitable for the vehicle platform and exceed industry requirements.

• HB. Fuller Supports EV OEMs and Tier manufactures by providing innovative materials, battery safety solutions, thermally conductive products, structural adhesives and sealing technologies. We provide complete turnkey solutions by including chemistry selection, product validation, production implementation, and technical support throughout the entire commercialization process

• Our patented EV Protect 4006 increases EV battery safety by improving protection against fires and thermal propagation. Additional key benefits include corrosion protection, semi-structural support, NVH properties, impact resistance, while helping to maintain a stable internal battery temperature from extreme external environments

• HB. Fuller’s next generation innovative adhesive and sealant solutions provide improved thermal management performance, increase structural rigidity, and seal against external environments. We are dedicated to developing products that help provide a safer battery for the future

The session addresses a simple joining of materials with the highest conductivity joint – keeping electrical resistance (and heat generated) to a minimum – reducing heat, reducing cooling systems energy consumption- in tern contributing to increasing vehicle range.

• Connecting aluminum, copper and other metals to connect leads and cells together

• How to connect different elements of the battery: E Clinching overview

• How the Tox e-clinching process works

• Solutions approach for the clinching process

• Solutions approach to oxide layer challenge

• Solutions approach for contact corrosion challenge

• Application samples

• E-clinching in multi-layer applications beyond two sheets

Bonding, sealing, and potting are key technologies in EV battery production that play a critical role in ensuring the performance, safety, and reliability of battery packs. In this session, we will delve into the key technologies of bonding, sealing, and potting in EV battery production, and highlight the current challenges associated with these processes.

Overview of Bonding, Sealing, and Potting in EV Battery Production:

In this session, we will provide an overview of bonding, sealing, and potting as key technologies in EV battery production. We will discuss the importance of these processes in ensuring the structural integrity, electrical performance, and protection against environmental factors for battery packs. We will explore the different types of bonding, sealing, and potting techniques used in EV battery production, including adhesives, sealants, and potting compounds, as well as their applications and requirements in different battery pack designs and chemistries. We will also highlight the advantages and limitations of these technologies in EV battery production.

Current Challenges in Bonding, Sealing, and Potting for EV Battery Production:

Bonding, sealing, and potting processes in EV battery production come with their own set of challenges. In this session, we will discuss the key current challenges associated with these processes. This may include issues related to process reliability, repeatability, and scalability, as well as material compatibility, durability, and performance under varying operating conditions. We will also discuss the challenges related to process automation, cost optimization, and environmental regulations, as well as the need for standardization and quality control in bonding, sealing, and potting processes.

Material Selection and Process Optimization for Bonding, Sealing, and Potting in EV Battery Production:

The selection of appropriate materials and process optimization are critical for the successful implementation of bonding, sealing, and potting in EV battery production. In this session, we will focus on the latest advancements in materials and process optimization techniques for bonding, sealing, and potting. We will discuss the properties and characteristics of different materials used in these processes, such as adhesives, sealants, and potting compounds, and their suitability for different battery pack designs and operating conditions. We will also explore the process parameters, equipment, and techniques used for optimizing bonding, sealing, and potting processes in EV battery production, including surface preparation, curing, and quality control.

Reliability and Durability of Bonding, Sealing, and Potting in EV Battery Production:

Reliability and durability are critical factors in EV battery production, as the performance and safety of battery packs depend on the integrity of bonding, sealing, and potting processes. In this session, we will discuss the latest advancements in reliability and durability testing of bonded, sealed, and potted battery packs. We will explore the testing methods, standards, and protocols used for evaluating the performance and durability of bonded, sealed, and potted battery packs under various environmental conditions, such as temperature, humidity, vibration, and mechanical stress. We will also discuss the failure modes, mechanisms, and mitigation strategies related to bonding, sealing, and potting in EV battery production.

• Current battery pack configurations – In the current, modular-based battery pack configuration, a minimum of two discrete thermal interface materials (TIMs) or “gap fillers” (GF) are typically employed to regulate the temperature of the modules and ensure safe, efficient performance

• Trade-offs with conventional modular design – Challenges with the old design include added weight and volume from the inactive portions of the module which ultimately translates into compromised pack energy density

• Next generation cell-to-pack configuration – Given these challenges, many EV and battery manufacturers are eliminating modules entirely and directly bond batteries to the cooling plate. This new module-free approach, referred to as “Cell-to-Pack” (CTP), reportedly increases volume-utilization space from 15-50%, depending upon battery cell design

• The benefits of thermally conductive gap fillers – Cell-to-Pack configurations offer numerous benefits, including increased volume-utilization space from 15-50%, reduction in the number of parts up to 40%, less expensive, lower energy density cells given the extra space, improvements to pack energy density, and more!

• Manufacturers are commonly faced with challenges related to labor availability, increasing costs and inflation, and improving quality – leveraging automation addresses many of these problems.

• Bonding automation offers numerous benefits, including improved process efficiency, reduced defects, the ability to explore new solutions, and significant cost savings. By streamlining tape and adhesive dispensing and application, automation enhances productivity, precision, and overall operational effectiveness.

• Partner with 3M to overcome your most critical bonding challenges, including tape and adhesive selection, design and simulation, and production automation.

• VHB™ Extrudable Tape is an innovative new solution that combines many of the benefits of a tape, with the automation capabilities traditionally limited to liquid adhesives.

• The RoboTape™ System for 3M™ Tape is an advanced solution that automates the application of 3M™ Tape in a process that was traditionally done manually.

• The 3M Bonding Process Center can help you see what is possible for automating your bonding application. Collaborate with 3M’s team of tape and adhesive automation experts to design a process that fits your application needs.

• The 3M Bonding Automation Network is a collection of system integrators, dispensing companies and robotics experts that 3M will connect customers with to implement solutions.

Advanced Bonding and Sealing Technologies for Battery Systems:

Bonding and sealing are critical processes in the manufacturing and assembly of battery systems, and they play a crucial role in their performance, safety, and sustainability. The session will discuss advanced bonding and sealing technologies for battery systems and explore innovative adhesive and sealant solutions that provide reliable and durable bonds, seals, and encapsulations for battery cells, modules, and packs. We will explore technologies such as high adhesion, thermal stability, and chemical resistance, that are well-suited for the challenging requirements of EV battery systems as well as the application methods, process optimizations, and performance testing of bonding and sealing technologies in battery system manufacturing, and their contribution to the sustainability and performance of battery systems.

Electric vehicle development to replace a mature ICE counterpart requires out-of-the-box thinking. The adoption of simulation-driven methodology is not only vital to the optimal usage of human resources and materials, but also the most viable solution to innovation. The consolidation of vehicle platforms by vehicle manufacturers demands a modular approach for electric motor design, which in itself lends to shared technology across vehicle platforms and manufacturers.

In this webinar, we present the value of using a unified modeling and simulation process that leverages the CAD-CAE connectivity for developing a new electric drive system or re-using one from an existing vehicle program. With the creation of a modular, fully-parametric and simulation-friendly electric drive model, it is possible to explore untouched design possibilities and test all possible scenarios in a more affordable time frame—thereby, accelerating the vehicle development program and preventing valuable engineering resources from being wasted.

• The industry has seen incredible advances in high voltage cell manufacturing over the past several years with the rise and increase of electrified powertrains

• But what about the low voltage battery? Is there a future? Learn more about the ever increasing role of the 12V battery in electrified powertrains and how much vehicles in the future will depend on it

Developing materials for next-generation EV batteries requires advanced analytical technologies such as Atomic Force Microscopy (AFM), NMR Spectroscopy, Energy Dispersive X-Ray Spectroscopy (EDS), Electron Backscatter Diffraction (EBSD), Wavelength Dispersive Spectroscopy (WDS), and Raman Imaging. This webinar will be divided into components:

• AFM – Applications of AFM that relate to nanoimaging of battery components and interfaces.

• SEM – Cleanliness, particle size, shape, and composition analysis of powders and electrodes using EDS, EBSD, and WDS.

• NMR –Leveraging diffusion and conductivity data from NMR for formulation development to gain insight into energy density along with charge/discharge performance.

• Raman Imaging – Investigating the cycling-induced chemical changes and degradation of cathodes, anodes and separators.

• In the news lately there has been a lot of discussion about battery fires because of Hurricane Ian. What might have prevented them?

• Did your EV have trouble getting the same range this winter?

• Worried your EV is going to overheat in the upcoming summer sun?

• In this webinar we will be discussing these extreme weather and climate conditions and what some H.B. Fuller innovative material solutions can do to help

A vision of self-driving cars propels the research and development of automotive LiDAR, a vital hardware providing distance and velocity information of a vehicle’s surroundings. Some LiDAR concepts are already heading toward production for automotive ADAS and industrial markets. Two newer concepts promise the greatest potential yet: frequency-modulated continuous wave (FMCW) LiDAR and time-of-flight (TOF) flash LiDAR. However, there are engineering challenges impeding their full adoption. This webinar reviews operation principles and challenges of different LiDAR concepts, a brief discussion on the LiDAR market, and a review of critical optical components such as photodetectors and sources.

• Fundamental test solution principles for challenges in demanding environments

• Ensuring flawless and reliable operation of potentially life-critical components and systems over the entire life of the equipment

• Techniques and results of signals from both LiDAR and facial recognition lasers from different smartphones

• Experience how LiDAR manages (or mismanages) navigating metropolitan city streets in a truly driverless Level 4 Robotaxi

• Why potting & encapsulation compounds are important for battery packs and different types of these compounds

• Role of lightweight components for EV battery packs

• Differences between syntactic and gas-foamed potting & encapsulation compounds

• Overview of 3M™ Glass Bubbles & role in lightweighting battery components

Fires caused by thermal runaway continue to be a significant issue in the evolution of EV battery packs. Now, as the EV marketplace approaches a tipping point, engineers are racing to address this challenge using various technologies. These include high-performance, pressure-sensitive adhesive (PSA) tapes used in combination with thermal materials that can assist in hindering thermal runaway propagation.

• How the evolution of EV battery pack design presents challenges to engineers seeking thermal runaway prevention solutions

• How and why PSA tapes are being incorporated into thermal runaway protection barriers in EV battery packs

• How PSA tapes offer numerous advantages in EV battery pack design, including flame retardancy, ease of assembly, corrosion prevention, and end-of-life-recyclability

• An overview of how to choose the right PSA tape for a specific application

• Propagation testing requires the intentional triggering of a single cell (or multiple cells) in a battery module or pack, to evaluate the ability of a specific battery design to reduce potential cell-to-cell propagation.

• This webinar discussed some of the common certification test methods currently utilized and the various requirements and criteria.

• Key Considerations for Thermal Management of Commercial Electric Vehicles – What You Need to Know about Controlling Thermals for the Battery Pack, Power Electronics and Passenger Comfort

• Common Architectures for Battery Thermal Management Systems, Electronic Cooling Packages and Cabin HVAC for Heavy Duty Vehicles

• Learn How to Identify the Thermal System You Need For Your Chassis Architecture

When repurposing EV batteries for stationary applications, new application-specific requirements must be validated on the repurposed packs.

One such test is propagation (otherwise called cell-propagation, thermal runaway, or single-cell-design tolerance).

As these test methods generally require modifications to an existing cell or battery pack to implement the test, repurposed batteries add a new challenge, as they are already manufactured, so modifications for testing must be implemented at the test site.

This webinar discusses these additional challenges and potential solutions for effectively performing these tests as well as potential preparation efforts that can be implemented on new EV batteries in expectation of future certification test needs.

• Understanding thermal conductive gap filler properties and their contributions to battery design and performance requirements

• Development of next-generation battery pack solutions, with a focus on vehicle end-of-life design in the age of circular economy

• From design concept to reality, technical solutions for scale up challenges; from pilot build to Gigafactory production

• 모듈/팩 내부의 기계적 및 열적 에너지를 관리

하는데 있어 압축 패트와 단열장벽의 역할을 대해 알아보자

• 발포제, 섬유, 포일, 에어로겔를 포함한 가능한 솔루션(해결방안)의 환경을 검토한다

• 열 이벤트 중에 에너지와 물질이 어떻게 거동하는지 이해한다

• 에어로겔 기반 열 장벽 PyroThin의 실제 테스트에서 열폭주 전이가 억제됨을 확인하라

• Pack level degradation analysis

• Predict capacity fade for real-life drive cycles

• Hybrid approach (Physics + ML) for faster and more accurate prediction

• Understand degradation at varying operating conditions

• This webinar will be looking at the three key characteristics, Safety, Performance, and Manufacturability, of adhesives and sealants used to construct battery packs

• Going through each step of construction, this will be a review the different applications for adhesives and sealants in a battery pack. For each of these applications, it will be expressed how those materials need to be engineered with those 3 key characteristics in mind.

• Key Safety concerns to be addressed include Cell to Cell Thermal Propagation, Electrical Arcing, and Water and moisture ingress.

• Key Performance attributes include Heat Transfer, NVH Performance, and Light Weighting.

• Key Manufacturability considerations for these materials will include cycle time, manufacturing cost, and ease of implementation/application.

• These features and many more will be evaluated and addressed in this upcoming webinar. See you all there!

• Overview of the battery manufacturing process

• Where automated weighing applications exist

• How weighing adds value in these applications

• How proper lifecycle management reduces risk

• Real application & success stories

• What are the design challenges of electrical insulation in EV battery and eMotor driven by major ePowertrain design trends?

• Major types of electrical insulation materials and their application areas today

• What are the major attributes (and disadvantages) of the major types of electrical insulation materials?

• Next generation electrical insulation technologies to enable new ePowertrain design and manufacturing

To maximize a vehicle’s safety and performance, battery engineers must strike a balance between electrochemical performance, cell life, and mechanical retention. It is a classic “Goldilocks Problem,” where li-ion cells do not want their clamping pressures to be too hard or too soft, and their preferences change over the vehicle’s lifetime.

• Learn how cell-to-cell barriers impact mechanical design

• Review simplified models for a balanced design

• Easily visualize your module’s mechanical lifecycle

• Conduct Monte Carlo studies of tolerance stacks