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.