Structural Bonding Technologies, Moving Batteries Forward
Structural bonding in batteries is key to unlocking safety and durability. Both mobility and stationary batteries must be strong and resist the harsh environments where they may be exposed. Sika has a range of structural bonding solutions for batteries from cell to battery pack and a range of chemistries to fulfill the most demanding specifications.
Benefits of Structural Bonding
- Higher Durability to help with safe battery design and longevity
- Higher Process Efficiency to bring down the costs of manufacturing
- Freedom of Design to help engineers work with novel materials
Crash safety standards in battery electric vehicles are stringent and with continuous revisions will likely only become more stringent as higher power densities are achieved in lithium-ion battery packs. Standards such as China’s GB 38031-2020 and Europe’s UNECE R100 Rev.3 emphasize the critical requirement that, in the event of a battery failure, the vehicle’s passenger compartment must remain protected for a defined period—ensuring safe evacuation. To meet these safety demands, Sika’s structural bonding solutions can be leveraged to enhance the strength and integrity of battery pack components, contributing to greater resilience under thermal or mechanical stress.
Batteries in stationary energy storage must stand the test of time. With increased demand on life cycles and safety it is key to ensuring the components within stay functional. Battery cells and modules require strong and efficient joining methods to allow for fast and efficient manufacture and good durability for the product lifecycle. Sika structural bonding solutions come in a range of different chemistries to support different technical specifications.
Structural Bonding Solutions
From high-strength epoxies to rapid-curing acrylics, Sika’s structural bonding portfolio delivers precision-engineered solutions tailored for the most demanding battery applications:
- SikaPower® - one component heat cured epoxies and two component room temperature cured epoxies offer highest strength for those most demanding applications
- SikaForce® - Two component polyurethane adhesives offer the highest diversity in strength, modulus and cure times. This system provides a range of materials for the most difficult specifications
- SikaFast® - Two component acrylic adhesives for fast application processes where minutes matter. For fast and lean assembly, a fast and durable system is required.
1C Epoxies and Spotwelding
Bonding and welding, whilst different joining techniques, can be brought together for a range of benefits. Structural strength developed by 1K heat cured epoxies allow manufacturers to build tough systems for protecting batteries. Application of adhesive is followed by spotwelding to hold structures together whilst they are subject to heat-treatments further in the process. This allows for convenient curing of e-coat solutions for example whilst also curing the adhesive providing ultimate durability and resilience.
Challenges in Welding
Welding is a high-cost operation in OEMs and as such Sika can support optimization of such a resource. Structural adhesives can be used in place of some welding functions to bring high value to partners. This allows for higher output with limited capacity in weld shops and other parts of the operation can utilize bonding techniques to strip cost out of part manufacture. There is a global shortage of skilled welders so reach out to our experts today to discuss how we can help optimize this precious resource.