Batteries and Battery Control Modules

Beneath the cool, quiet exterior of modern electric vehicles are powerful Li-Ion battery packs working in concert to facilitate the entire driving experience. Within each pack are a series of modules, which house the individual battery cells. At every level of the battery structure – and even outside the battery in the power inverter and engine control unit (ECU) – Henkel electronic materials are accelerating efficiency, reliability, battery life and, ultimately, safety. Bonding materials secure housings and lead frames for rugged conditions, while high-performance solders, adhesives and inks deliver reliable and responsive interconnects. Between each of the battery components, award-winning BERGQUIST brand thermal management materials are dissipating the heat generated by charging and discharging these workhorses. Safeguarding the entire battery system from top to bottom are Henkel protection materials to defend against exposure to fluids, harsh conditions, vibration and thermal shock.

Automotive Battery Applications

Bonding Materials for Batteries

Structural reliability for Li-Ion battery modules and battery packs.

As the global leader in adhesives development, Henkel’s award-winning LOCTITE formulations deliver uncompromising structural reliability for Li-Ion battery modules and battery packs. Within the module, rugged cell to cell and cell to module bonding are achieved with proven structural adhesives developed specifically for battery applications. These materials also ensure that the battery pack housing is securely attached and sealed, keeping fluids, dust and moisture out.

LOCTITE brand adhesive strength is found in the battery’s mechanically attached components as well. While screws and fasteners are designed to hold parts together, road vibration can loosen the threads and risk separation of copper lead frames or housings. LOCTITE thread locking adhesives eliminate this risk, securing mechanical parts for battery endurance.

Connecting Materials for Batteries

Proven interconnect solutions that deliver reliable and responsive electronic function to drive and monitor battery performance

Printed circuit boards (PCBs) within each Li-Ion battery module feed information about cell temperature, charging/discharging speed and overall module stress and performance to the master battery pack control module PCB, which manages battery pack operation. At the board level, Henkel’s proven interconnect solutions deliver reliable and responsive electronic function to drive and monitor battery performance. Advanced materials such as high-reliability solder alloys, temperature stable LOCTITE solder pastes and electrically conductive adhesives provide superior interconnection of components to substrates. Connection versatility is further enhanced with Henkel’s printed inks, which deliver electrical performance in space-constrained areas and also enable battery performance through printed temperature sensors for use in heating applications. 

Protecting Materials for Batteries

Henkel conformal coatings, encapsulants, and potting materials isolate and defend printed circuit boards, solder joints, and sensitive components from harmful conditions.

Once reliable assembly is achieved, multiple areas of power storage systems have to be enhanced with protective materials to fortify the battery ecosystem against moisture, corrosion, automotive fluids, vibration and thermal shock. Henkel conformal coatings, encapsulants and potting materials provide this defense for the PCB, isolating and protecting solder joints and sensitive components from harmful conditions. At the heart of the Li-Ion battery, individual battery cells are augmented with pre-treatment functional coatings of the cathode and anode metal, allowing strengthened bonds for improved conductivity. To keep contaminants out of the battery module and/or battery pack, Henkel TECHNOMELT low pressure molding offers a protective and secure alternative to conventional metal or plastic housings, while Henkel sealants provide an impenetrable barrier for pouches, battery pack housings and coolant systems.

Thermal Materials for Batteries

Flexible and effective heat management solutions for dependable Li-Ion battery function

New Li-Ion batteries now have power and energy densities that are unprecedented, making thorough thermal management of these high-voltage systems non-negotiable for proper operation. If any of the parts overheat – especially those that are flammable – battery work life and, more critically, safety are at risk. As the world’s top thermal management materials innovator, Henkel is partnering with today’s leading automotive companies to deliver flexible and effective heat management solutions for dependable Li-Ion battery function. Thermal management systems are required throughout the entire Li-Ion battery structure – in between the cells, from the battery to module housing and the module to battery pack housing. Henkel’s thermal interface materials – in liquid and pad format – permeate the Li-Ion battery system, providing insulation for safe in-use functionality, and contributing to the reliability of road-ready electric and plug-in hybrid electric vehicles.

Resources for Batteries and Battery Control Modules

Brochure: Materials for Power Storage Systems