ASC Growth Task Force

ASC would like to thank the following ASC member

companies that have contributed time, figures, information,
Online Resources
charts, pictures, and content for this white paper. Resources for individuals seeking
information on adhesives and sealant
Contributing companies
in automotive and battery & hybrid
electric vehicles (links):
n Cars, Trucks, and Buses Industry Page
on Adhesives.org

Selection Guides:
n OEM Body Shop Adhesive & Sealant
Selection Guide
n OEM Paint Shop, Trim & Final Assembly
Adhesive & Sealant Selection Guide

ASC Whitepapers & Presentations:

n Adhesives & Sealants as an Enabling
Technology for Lightweight, Safe,
and High Performing Steel Vehicles
n Adhesives & Joining Methods in Land
Transportation
n Adhesive Opportunities & Outlook
in Light Vehicles
n Adhesive Opportunities & Outlook
in Heavy Duty Trucks & Buses
n Adhesives & Sealants in Battery and
Hybrid Electric Vehicles

Guide By:
ASC Transportation Blogs:
n Adhesives.org/blog

Adhesive & Sealant Sourcing Tool:

n VendorSelect Tool

1 White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles
Introduction
Adhesives and sealants have played an important role in the advancement of vehicle
electrification technology and will remain at the forefront of the development of hybrid
(HEV) and battery electric (BEV) vehicle battery cells, modules, packs, and motors. Battery
technology in cars today has been adapted from consumer electronics. In order to meet
the more stringent requirements of the automotive industry, battery makers need to find
ways to achieve a 12 to 15-year vehicle life while operating at extreme temperatures and
enduring the shock and vibration generated from on and off-road driving. Adhesives and
sealants have played a significant role in meeting these challenges in many BEV and HEV
powertrain applications.

This paper will focus on the unique challenges and benefits that adhesives and sealants
deliver in EV powertrain applications and a provide brief overview of the amount of
adhesives used in the electric powertrains of these vehicles in 2018. The primary benefits
adhesives and sealants bring to electrified vehicle powertrains are:

• Joining components while shielding them from damaging shock and vibration

• Isolating components from shock and vibration, while creating a pathway to

conduct heat away from the cells and modules

• Conducting thermal energy to cool the battery cells and modules, but electrically
isolating the components to prevent shorts and reduce the risk of fire

Adhesives and sealants also play a significant role in body construction, paint, and vehicle
assembly of hybrid and battery electric vehicles. Since reducing the weight of EVs helps
extend their range, OEMs put significant effort into reducing the weight of components
of the body, interior, and powertrain. As a result, EVs often require bonding of
non-traditional or dissimilar materials, such as lightweight composite tailgates for SUVs
or hatchbacks. Those applications are similar to conventional vehicle construction and
are discussed in the following ASC publications: Adhesive and Sealant Selection Guide
for OEM Body Shops and Adhesive and Sealant Selection Guide for OEM Paint, Trim and
Final Assembly Shops. Refer to those guides for more information about adhesives and
sealants in light vehicle body construction and assembly.

White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles 2
 The Market for HEVs and BEVs
The global market for battery and hybrid electric vehicles 2018 Production of Electrified
is expected to grow significantly over the coming decade, Vehicles – 4.5 MM units
as HEVs and BEVs will be critical to helping OEMs meet Source: LMC, Industrial Market Insight
increasingly stringent carbon dioxide emission standards
across the globe, which are often expressed as increases in
required fuel efficiency in miles per gallon. Electric powered
vehicles, which include both HEVs and BEVs, accounted for
4.5 million of the 94 million vehicles produced in 2018, just
under 5% of all light vehicles produced. Over half of the 2018
production of electrified vehicles came from Asia, due to the
prevalence of hybrid electric vehicles in Japan and mandates
for battery electric vehicles in China. Many forecasts show
electric powered vehicles representing 25% or more of global
light vehicle production by 2030. This incredible growth rate
is predicated upon improvements in battery technology that
extend the range of electric vehicles, shorten EV recharging Figure 1: Production of
time, and reduce the cost of the batteries themselves. Electrified Vehicles by Region
Adhesives and sealants will play a big role in that growth
because they are enabling technologies that help EVs charge faster, travel further, and last longer.

Comparision of Historical and Enacted Passenger Car

Fuel Economy Standards
Source: ICCT, Industrial Market Insight

Figure 2: Comparison of Global Passenger Carbon Dioxide Emission Standards, stated

in US CAFE MPG Equivalent

3 White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles
Battery Components in BEVs and HEVs
The technology landscape in EV powertrains is changing rapidly, and there is little
standardization in the design and production of batteries for BEVs and HEVs. However, some
basic components can be found in all electric vehicle powertrains. The basic functions of the
battery cells, battery modules, and battery packs are described below:

Figure 3: Battery pack and components

Source: Henkel

Battery pack

Battery module

Cooling plate

Battery cells
Coolant line

Battery Cells
The battery cells are the most basic units that store energy for hybrid and electric vehicles.
There are three types of battery cells used in electric vehicles: cylindrical, prismatic, and pouch.
Each battery cell has an anode and a cathode that are separated from each other, but the
execution is different in each cell type.
Cylindrical cells are the most mature technology and the least expensive to produce per
kilowatt-hour (KWh) of energy storage. However, due to their circular cross section, they do
not pack as efficiently as other cells, making cylindrical packs larger and heavier than other cell
types.
Prismatic cells can be packed more efficiently than cylindrical cells due to their rectangular
shape, making them smaller and lighter, but more expensive, than cylindrical cell packs.
Pouch cells are the smallest and lightest cell technology but are also the newest and most
expensive. The small size and light weight allow OEMs to maximize usable vehicle space and
driving range of EVs, so developing technology to reduce the cost of pouch cells is a priority for
automotive supply chain.

White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles 4
 Pouch and prismatic cells experience more expansion and contraction during the usage cycle
than cylindrical cells, which factors into the selection of adhesive products such as foams.
Although relatively little adhesive and sealant is used in the manufacture of the cells, the cell
type has implications to the design of the modules and packs, as well as the requirements of
the adhesives and sealants used therein.

Figure 4: Pouch, cylindrical, and prismatic battery cells. Notice the cooling loop
running between the cylindrical cells. Cooling can be improved with the use of
thermally conductive adhesive beads or tapes.
Source: 3M

Pouch Cylindrical Prismatic

Battery Modules
A battery module encompasses a group of battery cells that are contained to protect them
from the shock and vibration of the automotive environment. The modules must be fashioned
in a way that allows the cells to be cooled (or heated, if necessary) and enables them to safely
and efficiently charge and discharge.

Battery Pack
The pack is the single power storage unit that is assembled onto the vehicle. It typically
includes several battery modules, controllers, and a cooling system. Battery packs for electric
vehicles are very large and consume a good deal of the space under the floor of the vehicle
and are enclosed and sealed to prevent intrusion of outside elements that would affect battery
performance or life.

5 White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles
Battery Electric Vehicles (BEV) vs
Hybrid Electric Vehicles (HEV)
Electric powered vehicles include both Battery Electric and Hybrid Electric powertrains. The
primary difference between BEVs and HEVs is the source of electricity that is stored in the
batteries. BEVs get power by being plugged in to an external power source, while HEVs have a
gasoline engine and generate their own electricity. Since a BEV must store a greater quantity
of energy than a HEV, the battery packs int the BEV are significantly larger. For example, BEV
battery capacity is generally in the range of 40 -- 75 KWh and they contain a few thousand
cells, whereas the high voltage HEV battery capacity may be 2-8 KWh and contains about 100
cells. As a result, BEV batteries are roughly five times the size of HEV batteries, and BEVs use
substantially more adhesive than HEV on a per vehicle basis. On average, a BEV powertrain
contains 7 lbs of adhesives or sealants while a HEV powertrain contains under 2 lbs.
Each OEM has its own philosophy regarding the selection of cells and the design of modules
and packs. Cylindrical, prismatic, and pouch cells are in production vehicles today, and there
is little standardization of componentry or design. Modules and packs can be made of metal
or plastic and use adhesives and sealants to varying degrees. Typical uses of adhesives and
sealants in battery packs and modules are discussed below.

Adhesive & Sealant Consumption in HEV & BEV

Batteries and Motors, Global Total 2018
Source: Industrial Market Insight

Figure 5: Global Adhesive & Sealant Consumption in HEV & BEV Batteries & Motors, 2018

White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles 6
 Adhesive and Sealant Applications
in Battery Modules
Each module contains groups of battery cells. The cells generate heat during their usage cycle,
and they must be cooled to operate efficiently and safely. Cooling is most commonly achieved
by system that circulates a glycol-based fluid through a cooling plate, similar to the way
radiator works in a gasoline engine. The cells must make firm contact with the cooling plate
in order for heat to be efficiently conducted away by the coolant. Thin layers of gap-filling,
thermally conductive adhesives are used to bond the cells to the cooling plate and ensure good
contact with the plate. Pads of conductive thermal interface material can be used for this
purpose instead of adhesives. Adhesives can simplify the assembly process and eliminate the
inventory of thermal interface pads.
Although thermally conductive, the adhesive must electrically insulate the cells from the
cooling plate to prevent a short circuit. Therefore, high dielectric strength and fire resistance
are musts for adhesives in this application. Epoxy, silicone, polyurethane, and methacrylate
adhesives are used to bond battery cells to the cooling plates.

Figure 6: Thermal interface

material bonding battery
component to heat sinks.
Source: Henkel

Heat sink Electronic component

Thermal interface pad

Although the cells in the module are fixed to the cooling plate, they sometimes need
additional support and protection from the mechanical shock and vibration experienced as the
vehicle travels, or if it is involved in a collision. This support and protection can be provided
through the use of adhesive or sealant foams or tapes. Adhesives used in these applications
must have sufficient flexibility to allow for expansion and contraction of the cells in the usage
cycle. Flexibility is particularly important with prismatic and pouch type cells, which expand
and contract more than cylindrical type cells as they charge and discharge.

7 White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles
There are two different methods of protecting the battery cells using adhesives or sealants:
Adhesive and Sealant Foams can be used to fill a portion of the module cavity and
surround the cells, holding them in place. Foams that encase battery cells can be thermal
conductors or insulators, depending if the battery cells are actively or passively temperature
controlled. For actively temperature conditioned systems, where the cells are both heated
and cooled to keep them in the ideal operating temperature, insulating foams are desired.
In either case, the foam must be an electrical insulator to prevent the creation of a short
circuit. Adhesive and sealant foams can also be formulated to slow or stop fires in the event
a battery becomes overheated or damaged. Bulk-dispensed foams are easy to deliver to fill
irregular shapes, such as the gaps between cylindrical battery cells.
Tapes or Ribbons of Extruded Adhesive can be wrapped around the cells. Tapes allow
for better control of the amount and location of adhesive compared to bulk dispensed
adhesives or sealants. This minimizes the weight and cost contribution of the adhesive or
sealant to the battery pack. Reducing the weight of the pack is essential in EV because lighter
weight equates to extended battery range. Application of tapes can also make for easier
assembly, particularly for prismatic cells, because the rectangular shape of the cell lends itself
to tape dispensing.

Figure 7: Foam encapsulating

battery cells inside a battery
module. Foams can be used
to support and protect battery
cells and may also slow or stop
the spread of fire if there is a
problem with the battery.
Source: H.B. Fuller

White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles 8
 Adhesive and Sealant Applications
in Battery Packs
Automotive battery packs contain multiple battery modules, controllers, and a cooling system.
The battery pack is sealed with a mechanical gasket, sealant, or adhesive to protect the
contents from outside elements, such as water, dust, road salt, and automotive fluids. Since
the pack enclosures can be made of steel, aluminum, or a variety of composites, adhesion to a
wide variety of substrates is important. Battery enclosure materials often do not have typical
automotive pretreatments, such as e-coat, so the ability to bond to substrates such as bare
aluminum and composites is a factor into adhesive selection.
The pack itself can be mechanically fastened or bonded to the vehicle body or frame. Packs are
positioned so that the vehicle frame will support and protect them from damage in the event
of a crash. Structural adhesives can be used not only to join, but to add strength and stiffness
to the completed assembly, which allows for the use of lighter materials and structures for the
pack. Structural epoxies and polyurethanes are generally selected for these applications due
to their high strength and the ability to bond to metals, as discussed in “Structural Bonding
of Light Vehicle and Heavy Truck Bodies and Cabs” on pp 11-16 of the ASC OEM Body Shop
Adhesive & Sealant Selection Guide. Crash-toughened adhesives are used in some applications
because these adhesives absorb crash energy with less deflection of the frame, which helps
reduce potential for damage to the batteries in the event of a crash.
The structural and crash toughened adhesives are similar to adhesives used in OEM body shops,
but must cure at room temperature because the battery pack is not subjected to the heat of
the paint or e-coat ovens used to cure adhesives applied in the OEM body shop.

Figure 8: Light vehicle frame with battery pack installed

Source: Sika

9 White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles
Inside the battery pack, adhesive and sealants are used to seat the modules and fix them in
position. Similar to bonding cells inside the module, the adhesives and sealants must allow for
efficient heat transfer to the cooling system by being thermally conductive and filling gaps to
ensure firm contact is made between the surfaces. A wide variety of technologies are used in
this application, including silicone, epoxy, polyurethane, and methacrylate adhesives. In some
instances, tapes and thermal interface pads are also used instead of bulk applied products.

Serviceable and Non-Serviceable Battery Packs

There are two schools of thought on battery packs. Some have components that can be
replaced if they malfunction, while other packs are not intended to be serviced and must be
replaced if they have problems. There are implications to adhesives or sealants used in the
bonding or the sealing of the battery pack.
Non-Serviceable Battery Packs – Have a permanent enclosure that is mechanically
fastened, welded, or bonded with a structural adhesive. Since the pack is not intended to be
opened, adhesives that will cause substrate failure when removed are acceptable for these
applications. In fact, this can be a benefit, as there will be evidence that the battery pack has
been accessed for an attempt at an unauthorized repair. Non-serviceable battery packs can be
bonded with a structural polyurethane, epoxy or methyl-methacrylate adhesives, since there
is no concern about the substrate remaining intact if the pack is opened. Non-serviceable
batteries can also use flexible adhesives, sealants, or gaskets to seal the pack.
Serviceable Battery Packs – Have a cover that can be removed and replaced. Serviceable
batteries can use a mechanical gasket or a flexible polyurethane, silicone, or silane terminated
product to seal the case. Removal of the pack lid may require cutting the adhesive in a manner
similar to that of automotive
glass replacement, which is
acceptable as long as the cover Figure 9: Cover of a battery pack bonded with
remains fit for use. OEMs desire an adhesive or sealant
to use a seal that can be reused Source: Sika
rather than replaced when the
pack is opened and resealed, a
challenge that manufacturers of
adhesives and sealants, as well as
mechanical gaskets, are working
to address.
Whether serviceable or not,
adhesives and sealants used
for bonding battery covers
must be fire-resistant and are
often required to be electrically
resistive, in addition to meeting
typical automotive environmental
and chemical exposure tests.

White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles 10
 Adhesive and Sealant Applications
in Electric Motors
Aside from the battery applications, adhesives are also an enabling technology in high
performance motors that power electric vehicles. Adhesives bond permanent magnets to
rotors and stators, and in some cases, for the encapsulation of the stator. Epoxies are generally
used for these applications due to the high operating temperatures ranging from 180 to
220°C, but cyanoacrylates are sometimes also used in magnet bonding applications. These
adhesives must be thermally conductive to allow the motor to cool during operation, which in
turn permits greater power output for a given motor size. They also require high temperature
resistance, due to the heat generated by the motor during operation, and resistance to the
synthetic oils that are used to lubricate it.
Electric motors also have multiple gaskets that are used to seal the housing and keep water,
dust, and other contaminants away from the motor. These gaskets require resistance to the
same temperature and fluids required for the magnet bonding and stator encapsulation.
Silicone sealants, formed-in-place gaskets, or pre-formed gaskets are used for motor gasketing
applications.

Figure 10: Motor and stator adhesives and sealant applications.

Source: 3M Motor housing sealing
Stator magnet bonding

Rotor magnet bonding

Quantity of Adhesives and Sealants

Used in BEV and HEV
About 15 MM lbs. of adhesives and sealants were used in the powertrain of the 4.5MM
HEVs and BEVs produced in 2018. This includes BEVs, such as the Tesla model 3, S, and X,
the Nissan Leaf, and the Chevy Bolt, as well as several models that are produced in China
for the local market by OEMs such as BAIC, SAIC, BYD, Geely, and others. The Toyota Prius is
nearly synonymous with “hybrid” or HEVs, but this category also includes hybrid powertrains
incorporated into mainstream nameplates from many major OEMs, such as the Honda Accord,

11 White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles
Ford Fusion, and Chevy Malibu. Although this averages to 3.3 lbs. of adhesive and sealant in
each powertrain, the average quantity consumed per vehicle is not a good measure due to
the substantial differences in design and engineering of the batteries and components. Some
OEMs use adhesives and sealants extensively, while others prefer mechanical fasteners and
thermal interface pads rather than liquid dispensed products.
BEVs use a greater amount of adhesive and sealant on a per unit basis than HEVs because the
battery packs are larger. BEV batteries have capacities in the 40-75 KWh range versus a 2-8 KWh
capacity of the high voltage battery on a HEV, and the packs of BEVs are roughly five times the
size of a HEV pack. Although BEVs accounted for only a third of the electric vehicles produced in
2018, they used nearly two thirds of the adhesives and sealants overall for both types of vehicles.
Sealing of packs and modules is the largest application and represented over 40% of the mass
of adhesives used. This is the bonding of the perimeter of the enclosures for the packs and
modules that use adhesives or sealants rather than a mechanical gasket.
Thermal interface bonding was the second largest application and accounted for just under
40% of the adhesives and sealant volume. These are thermally conductive, electrically resistive
adhesives that are used to bond battery cells to cooling plates or tubes.
Battery cell encapsulation and motor bonding and gasketing accounted for about 10% of the
mass of adhesives and sealant dispensed.

Volume of Adhesives & Sealants in HEV & BEV Powertrain Applications

15.2 MM lbs (2018)
Source: Industrial Market Insight

by Vehicle Type by Application Motors:

magnets, stators,
gasketing; 11%
HEV;
36%
Battery cell
Thermal encapsulation;
interface 10%
bonding;
37%

BEV;
64%
Pack & module
bonding /
sealing; 42%

Figure 11: Global adhesive and sealant use BEV and HEV battery packs, modules,
cells, and motors by vehicle type and application in 2018.

White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles 12
 Summary
Adhesives and sealants are poised for growth in both HEV and BEV powertrain applications because
they help component manufacturers and OEMs address critical performance, safety, durability, and
manufacturing challenges confronted during the introduction of these electrified vehicles.
As battery technology has evolved from consumer electronics to automobiles, the adhesive and sealant
industry has developed no-compromise solutions with an improbable combination of physical, mechanical,
thermal, and electrical properties in easy to use products. Adhesives and sealants help solve difficult
fastening issues with multiple substrates, protect batteries from mechanical shock and vibration to make
them more durable, assist in cooling to improve efficiency and extend life, and increase safety by preventing
electrical shorts and suppressing fires. As designs mature and with annual production volume of BEVs and
HEVs forecast to increase significantly from the 4.2 MM vehicles produced in 2018, the outlook for adhesives
and sealants in electric vehicle powertrains is bright.

Find the Right Adhesive or Sealant Supplier or

Manufacturer for OEM Light Duty Car/Truck Applications
The Adhesive & Sealant Council has a great web-based tool that allows
you to search for Adhesives and Sealants by market.
The online tool guides you through a customized list of parameters in
order to deliver a clickable list of suppliers and manufacturers available
to meet your needs.
Try it now at www.adhesives.org/VendorSelect
The following ASC Member Manufacturers and Suppliers provide adhesives and/or sealants in the
automotive and battery & hybrid electric vehicles market:
*Note: Logos are clickable.

Raw Material Suppliers:

13
Manufacturers:

Affiliates:

White Paper: Adhesives and Sealants in Battery and Hybrid Electric Vehicles 14