Thermally Conductive Materials for Electric and Hybrid Vehicle Batteries

Thermal Management of Electric Vehicle Power Sources

Responding to a strong and increasing demand in innovative manufacturing concepts for electric and hybrid vehicle batteries, Polytec PT provides adhesives, pottings and greases with high thermal conductivities that are customized with regard to processing parameters, thermal and mechanical properties, and service durability. The need for power dissipation from the cell to the surrounding medium requires an ever effective thermal management in order to ensure an efficient, reliable and long-time operation of the components.

The assembly and integration of single hard-case (prismatic) or pouch cells to build a secure and durable battery system requires mechanical fixing, thermal management, and vibration damping. Conductive adhesives provide an ideal solution thanks to their:

  • Structural strength
    Vibration resistance
    Dielectric strength
    High thermal conductivity
    Good chemical resistance
     

Apart from batteries, there is an increasing demand for adhesive bonding, sealing and encapsulating of other electric and hybrid vehicle parts like motors, converters, control units, and power electronics devices. Regardless of the application, good thermal management improves durability of the end product and hence positively affects its energy efficiency and eco-friendliness.

Alternatives to Mechanical Fixing, Brazing and Welding

The new high thermally conductive products make adhesive bonding an increasingly attractive alternative to welding, soldering and mechanical joining. Especially the epoxy-based adhesives care for both structural strength and durability of the adhesive joint.

Thermally Conductive Materials from Polytec

Polytec provides both thermal conductive adhesives, silicone-fee thermal greases and gap fillers, all with a design toward ease of use and durability. In coordination with customer and market requirements, we are constantly developing new, improved adhesives and pottings with high thermal conductivities towards 2 W/mK and more, customized to the respective application.

Thermally Conductive Adhesives and Pottings

Product Code Polytec TC 417 Polytec TC 451 Polytec TC 418
Features Potting of large cavities, excellent chemical and moisture resistance High Tg, bonding, potting and sealing High thermal conductivity, flexible version available
Consistency Flowable black paste Flowable soft black paste High viscous flowable gray paste
Cure Schedule 23 °C / 24 hours 23 °C / 16 hours 23 °C / 48 hours
Operating Temperature Range -55 °C ... 180 °C -55 °C ... 180 °C -55°C ... 160 °C
Thermal Conductivity 0.8 W/mK 0.7 W/mK 1.6 W/mk

Thermal Greases, Pads & Gap Fillers

Product Code AOS 52022 Sure-form 52153 Micro-Faze A
Features Non-Silicone, thixotropic thermal grease Highly viscous, dispensable gap filler Dry to touch Silicone-free thermal pad
Consistency Smooth, off-white paste Gray paste Thermal Interface film
Volume resistivity 1.65 x 10^14 ohm-cm 2.15 x 10^14 ohm-cm n.a
Operating Temperature Range -40 °C to 200 °C -40 °C to 200 °C n.d
Thermal Conductivity ASTM D 5470 0.9 W/mK 3.5 W/mK 2.8-4.5 W/mk depending on film thickness

Sure-form and Micro-Faze are registered trade marks of AOS Thermal Compounds Eatontown, NJ