Resins That Address Heat Challenges Of Hybrid and EV Batteries

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They deliver effective thermal management solutions for improving battery safety, reliability and longevity

The demand relating to safe, efficient and quick charging of high-capacity battery packs for hybrid and electric vehicles has been rapidly increasing. One of the biggest concern areas for battery designers is the impact of heat impact that can affect battery performance, as drivers switching over from traditional fuel vehicles to electric expect no compromise in performance.

Implementing effective thermal management solutions can significantly improve battery performance, safety and reliability, thereby leading to increased battery life. For this, new resin solutions for EV customers have been developed that are proven to succeed in solving heat, performance and protection issues.

Primarily developed for the protection of LED drivers, the SC4003 is a thixotropic two-part silicone potting and encapsulating resin that secures a battery at the base and ensures effective heat dissipation. The thermal conductivity of SC4003 is 1W/mK and has high-temperature properties, suitable for use in applications where the operating temperature is up to 200 degrees Celsius, while its flexibility allows for temperature cycling. Its thixotropic nature and good flow characteristics make it an excellent choice for extremely tight spaces or difficult geometries. The process simply ensures that 30 per cent of the battery height is filled with resin.

Another key product for battery protection includes the thermal gap filler – GF400. It is a highly effective heat transfer solution, providing excellent thermal performance at 4.0 W/m.K. The two-part, liquid silicone-based filler is a thick liquid that can be easily applied around different shaped housings with low stress on components. After application, the gap filler can be cured at room temperature or accelerated with heat, with a wide operating temperature range between -50 degrees Celsius to +200°C. The low viscosity of GF400 enables easier dispensing and curing.

To seal the battery pack, the ER6001 two-part epoxy encapsulation resin has excellent chemical resistance and wide operating temperature range, performing exceptionally at high temperatures. ER6001 is suitable for a wide variety of applications within the automotive electronics industry for the protection of EV battery packs.

And finally, the ER2221, a highly thermally conductive resin with low viscosity, helps achieve prolonged battery life and high efficiency, making it ideal for potting cells within electric vehicle batteries. The UL94 V-0 approved epoxy potting compound can withstand long durations at high temperatures and can assist with securing cells in place whilst dissipating the heat away to the surroundings. The resin effectively creates a protective shield around the battery and enables excellent adhesion, high-temperature resistance, high thermal conductivity and retention of characteristics throughout the thermal cycling process. The ER2221 has an operating temperature of 150 degrees Celsius and an advanced thermal conductivity value of 1.20W/m.K.

“Thermal management is a pre-requisite for efficient battery operation in electric and hybrid vehicles, particularly with all the various global climatic conditions and hostile environments that vehicles are subjected to. Batteries produce vast amounts of heat during operation and whilst charging,” said Ron Jakeman, Managing Director at Electrolube. “We are delighted to introduce our Thermal Management and Encapsulation Resin Solutions to the battery industry to improve their performance and lifetime. We are looking forward to learning about customer requirements and advising on the efficient solutions we offer.”

All product ranges are manufactured at Electrolube’s BS EN ISO 9001, ISO 140001, “IATF 16949:2016, OHASA 18001 and AS/EN 9100 Series accredited factories in the UK, China and India.


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