January 13, 2025
Battery pack adhesive solutions that incorporate thermally conductive adhesives provide thermal management systems with the ability to safely dissipate excessive heat from main battery parts under high load. Since batteries in electric vehicles (EVs) store and deliver significant amounts of energy, they are prone to generate heat. This causes the liquid catalyst electrolyte inside the battery to start to evaporate, damaging the battery’s internal structure and causing the lead plates inside it to corrode, shortening the battery life.
Therefore, there is huge pressure on the manufacturers and designers of EV batteries to select the right thermally conductive adhesive. These adhesives are particularly suited to providing a secure mechanical connection between parts and minimizing thermal resistance, making them crucial for high-performance battery applications.
Product Name | Company | Type of Adhesive | Thermal conductivity | Temperature Range | Curing Time | Key Features | Applications |
TC 2035 | DOWSIL | Silicone based | 3.3 W/mK | -45°C to 200°C | 10 minutes at 150°C or 30 minutes at 125°C | High thermal conductivity, Reduced thermal resistivity, Stability under high temperature | Battery Packs, Boards and Assemblies |
TC-2030 | Dow Corning | Silicone based | 2.7 W/mK | -45 to 200°C | Room-temperature curing within 24 hrs, 1-2 hours at 100°C | High thermal conductivity, Maintains structural integrity, High Reliability | EV Battery packs, electronic enclosures |
EA 9497 | Henkel Loctite | Epoxy based | 1.4 W/mK | Upto 200°C | Room-temperature curing within 24 hrs | High temperature resistance, high compression strength, strong adhesion under thermal stress | Electronic assemblies and battery packs |
SE 4486 | Dow Corning | Silicone based | 1.59 W/mK | -45 to 200ºC | Room-temperature curing full capacity in 4-7 hrs | Good dielectric strength, Non-corrosive | Bonding in consumer electronics |
8329TCM | MG Chemicals | Epoxy based | 1.4 W/mK | -40°C to 150°C | 24 hours room temperature or 1 hour at 65 °C | Strong electrical insulation, High mechanical strength, Strong resistance to humidity |
Attach heat sinks |
PyroDuct 597-A | Aremco | Ceramic based | 9.1 W/mK | Upto 927°C | Room-temperature curing within 1-2 hrs | High temperature resistance, Electrical conductivity, Corrosion resistance | Battery packs in high-temperature environments, industrial electronics |
THERM-A-GAP Gel 30 | Parker Chomerics | Silicone based | 3.5 W/mK | Upto 200°C | Doesn’t need curing | Easily dispensable, Low thermal impedance, High bulk thermal conductivity |
Battery pack gaps, thermal interface for irregular surfaces |
TCOR | Electrolube | Silicone based | 1.8 W/mK | -50 to 230°C | 24 hours at 20°C | High bond strength, Wide temperature range, High thermal conductivity |
EV batteries, electronic modules, applications requiring RTV flexibility |
PRIMA-SOLDER (EG8050) | AI Technology | Silver filled epoxy | 7.9 W/mK | 80 to 100 °C | 120 hours at 25 °C or 2 hours at 125°C | High melting point, Excellent Wetting Properties, Non-corrosive | Circuit boards, Battery pack assemblies |
UR5097 | Electrolube | Polyurethane based | 0.65 W/mK | -40°C to 110°C | Room-temperature curing within 24 hrs | High thermal conductivity, Flame retardancy, Moisture and Chemical Resistance | EV battery modules, Electrical circuits. |
Each of these adhesives offers unique properties suited for different applications. Still, the overall goal remains the same, which is to facilitate the movement of heat from the battery pack while providing adequate protection to the battery pack.
Understanding the different types of thermally conductive adhesives is essential to choosing the right one for battery pack applications. Here’s a closer look at three primary types: epoxy, silicone, and polyurethane.
Epoxy adhesives are most commonly used in battery pack applications due to their good mechanical strength and compatibility in adhering to the cellular structures of metal and ceramics . Therefore, epoxy adhesives can be used for bonding battery systems involving metals, ceramics, and composite materials.
Figure 1: Various types of Epoxy (Loctite® AA H4500 (right) and PRIMA-SOLDER™ (left)).
Due to the above-mentioned benefits, epoxy is an excellent choice for various applications. However, they can be more brittle than the other two types, which limits their use in situations needing flexibility.
Silicone-based adhesives are highly valued for their flexibility and excellent thermal stability, especially in high-temperature situations. They are selected for applications where vibration resistance and temperature fluctuations are a concern.
While silicone adhesives may not provide the same bonding strength as epoxies, their durability in extreme conditions makes them a preferred option for battery pack applications.
Polyurethane adhesives are less commonly used for battery pack applications but are considered where flexibility and impact resistance are concerned. They have the ability to stretch due to polymer and fill the minute gap without causing the interface to fail.
However, polyurethane glues usually have lower thermal conductivity than epoxies and silicones, which limits their use in systems that require high levels of heat transfer.
Thermally conductive adhesives play a crucial role in the design and production of efficient battery packs and other advanced battery systems. With the increasing need for energy storage solutions, managing heat effectively has become vital for prolonging battery life, maintaining efficiency, and ensuring the safety of these systems.
Figure 2: Thermally conductive adhesives are important for designing efficient battery pack systems.
Choosing the right adhesive requires considering several factors: thermal conductivity, mechanical strength, flexibility, and resistance to environmental conditions. Epoxy, silicone, and polyurethane adhesives each have their benefits, and the best choice depends on the specific requirements of the battery system. As adhesive technology continues to advance, manufacturers will have more options to enhance thermal management.
Enhance your battery’s thermal performance with Thermtest solutions. Reach out to our experts today for tailored guidance and solutions!
Thermally conductive adhesives like epoxy, silicone, and polyurethane are used in EV batteries since they provide not only strong bonding but also efficient heat dissipation.
The best thermally conductive adhesive depends upon its application. For high strength, epoxies like Henkel Loctite EA 9497 are most commonly used. On the other hand, if high flexibility and temperature stability are required silicone adhesives like Dow Corning TC-2030 are ideal.
8329TCM. (2024, September). Retrieved from DigiKey.com
AI Technology PRIMA-SOLDER EG8050-E Epoxy Paste Adhesive 3 cc EFD Syringe. (n.d.). Retrieved from https://www.ellsworth.com
Dow Corning TC-2030. (2013). Retrieved from Ellsworth Adhesives: https://www.ellsworth.com
Dow Corning®SE 4489 Thermally Conductive Adhesives. (2010, September). Retrieved from Octopart.com
DOWSIL™ TC-2035 CV Adhesive. (2021). Retrieved from Dow.com: https://www.dow.com
Electrically and Thermally Conductive Adhesives and Coatings. (n.d.). Retrieved from https://www.aremco.com
LOCTITE® EA 9497. (2014, October). Retrieved from Henkel adhesives: https://www.henkel-adhesives.com/tz/en/product/structural-adhesives/loctite_ea_9497.html
RTV Thermally Conductive Oxime. (n.d.). Retrieved from https://electrolube.com/
THERM-A-GAP GEL 30 High Performance Fully Cured Dispensable GELS. (n.d.). Retrieved from https://ph.parker.com
Thermally Conductive Polyurethane Potting Compound. (n.d.). Retrieved from https://electrolube.com