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125yearsVol. 198 • Issue 3

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ELECTRO-MOBILITY
development crystallizing
around semi-conductors

New generation ofJOINING MATERIALSfor NEV Assembly

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visit ai.com.ai“Besides affordability – which remains the number one challenge inthe transition to electric powertrains – OEMs have to deliver to theircustomers reliable, durable and safe vehicles in order to take thelead in this developing segment.”– Dr. Nicolas Morel, Business Development Manager - E Mobility, Sika Industry & Automotive. Page 22

innovation

Towards lighter,stronger and safer
e-vehicles
By: Tony Davidson

For battery systems, Sika
supplies adhesives and sealants thatmeet high technical requirements forhigh temperature resistance andhigh thermal conductivity.

Innovation in the development of electric vehicles includes the use of new materials, aswell as new combinations of materials in order to provide rigidity and safety while reducing
weight in order to increase range.
This has led to the development of a new generation of adhesivescapable of securely bonding different materials, and combinationsof materials. In turn, electric vehicle manufacturers are now able
to make increasing use of non-traditional materials such asaluminum, magnesium and carbon fiber-reinforced plastics, aswell as lighter gauge sheet metal. Inside the battery compartment
there are also challenges in managing heat.
These materials create unique challenges in thevehicle assembly processes, which includes joining

Dr. Nicolas Morel,Business Development Manager- E Mobility, Sika Industry.

or bonding, and introduce new challenges in termsof durability, vehicle dynamics and crash performance.
Automotive Industries (AI) asked Nicolas Morel,
Global Product Marketing Manager, Sika Automotive, what hesees as the main challenges facing OEMs in the manufactureof electric and hybrid vehicles.
Morel: Besides affordability – which remains the number one
challenge in the transition to electric powertrains – OEMs have todeliver to their customers reliable, durable and safe vehicles in order28

to take the lead in this developing segment. Other challenges include
resolution of the charging network, charging cycle time, driving
range and vehicle top speed. These are key parameters for end user
adoption between the numerous brands present in the market.
Challenges do not only affect the OEM, but also Tier partners
along the supply chain. Nor is it only the passenger car sector.
The same challenges affect the transportation segment at large.
Combinations of developing platforms – hybrid or native
BEV (battery electric vehicle) – present a mix of design options on component assembly, body structure, materials mix and the incorporation of NEV(new energy vehicle) or full electric drivetrain
components. Adhesives and sealants play an
expanded role in all cases. Therefore, specialist providers like Sika need to provide a deep
range of technologies.
AI: How do your company’s products
help meet these challenges?
Morel: Sika is a key supplier for bodystructure and component assembly technologies,
and is well established in that regard. Our solutions
also run deep into the new powertrain systems. Key factorsthat directly drive performance and safety of NEVs are heat
control and dissipation. Heat is the enemy of high performing
battery systems. Our latest innovations for thermal management
in battery systems include silicone-free thermal conductive
adhesives and gap fillers providing the best performance for
optimum heat transfer in battery packs and modules.

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Electrical coating and potting solutions offer protection
against vibration, moisture and chemical agents.
Moreover, we have recently developed 2-component epoxy
resins for e-motor stator encapsulation that enhance motor
performance while facilitating design options, weight reduction andthroughput improvements in manufacturing by cutting cycle times.
Our solutions include multiple dielectric potting chemistries forcontrollers throughout the vehicle and on board chargers, as wellas harnesses and connectors. Bonding and sealing enclosures is a
Sika core competency, and we are there as well.
AI: Light-weighting for greener vehicles, as well as
comfort and safety are of paramount importance – how
can Sika help in all three areas?
Morel: Lightweighting, comfort and safety are not new trends
in our automotive business. Identified as megatrends morethan a decade ago, Sika has invested in the development andin developing new bonding solutions that overcome challenges
in diverse applications; adhesion on bare metals, plastics andcomposites while offering answers to heat and glycol resistance,
as well as to accommodate the constant delta-alpha effects when
joining multi-materials – all in cold assembly process conditions.
AI: What are the challenges in battery box construction for
EV cells? How has Sika managed to find effective solutions?
Morel: There are two primary areas where selected materials
need to outperform in the battery cell operating environment: heattransfer and fire resistance. Sika offers a wide range of thermal
conductive and fire-resistant silicone-free bonding systems thatallow optimal assembly and long-term performance of battery
cells. Further, we combine our intumescent coatings to avoid
heat runaway in battery modules, and to protect in an ultimate
failure situation by suppressing the spread of smoke and fireoutside of the battery box. Our product range specific to battery
components has been tailored to where we can best add value
with performance, or simply put our products offer value add.
AI: Give us an idea of the importance of R&D to Sika andhow the company works with customers to find solutions
for the vehicles of tomorrow?
Morel: Courage for Innovation is one of our company’s fivecore values. It is echoed in the culture of our company, and in theway we approach our customers. We walk the talk. Customer
partnership is in our DNA.
R&D is a vital investment. We seek interaction and customer
partnerships that lend themselves to further technological reach.
We are also an anticipatory organization, which means thatproducts which are available today were blueprinted several

We are, and continue to be, a solution provider inour core competencies of bonding, damping, sealing,reinforcing and protecting to help to build better
vehicles no matter what form they take.”application of innovative solutions in those three segments. It has
been, and continues to be, a part of our DNA.
Products which have been proven to meet those challenges include our novel joining solutions for multi-material assembly, lightweight reinforcement systems for crash performance improvements;
as well as our industry-leading full range of acoustic parts and sounddamping solutions that perfectly complement electric power train requirements. NEV powertrains offer further opportunity for deploymentof high-performance Sika technology with a product range that has
been selected and readied in advance of the current state.
AI: What are some of Sika’s latest technologies for newvehicles and how do they compare to traditional adhesives?
Morel: In a simple view, one of the biggest challenges thatcomes along with electric vehicle design and manufacturing is
the multiplication of, and type of materials used in constructionof the electric power train. The challenges are answered with ourextensive range of products and knowledge because we haveprepared in the past for the future.
We also have a broad pallet to select from based on our global
portfolio – 1C, 2C and boosted PUR, silicone, STP, MMA, epoxy,hybrids, dispersion coatings, hotmelts and PSA. There are manydifferent approaches between our customers that are answeredby our full product range approach. We continue to be creative
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years ago based on shared vision and to address megatrends.
Our R&D efforts continue to yield tomorrow’s products – realizing
tomorrow is often five years away. The entire organization remains
engaged in partnership relationships with customers and withindustry consortiums which contributes to a clearer view oftomorrow’s vehicle needs no matter what form they take.
AI: What is Sika Automotive’s strategy over the next five
years in terms of the fast-changing automotive landscape?
Morel: We continue to be customer focused and very active inthe market segments we serve, while we continue to analyze and answer global megatrends. We are not driven by headlines, but throughproactive analysis of customer future needs. If you are referring directly
to E vehicle powertrain transformation, a key to a fast-changing environment is to realize the opportunity that change presents.
We are, and continue to be, a solution provider in our corecompetencies of bonding, damping, sealing, reinforcing andprotecting to help to build better vehicles no matter what form
they take. Over a five-year planning timeframe, we expect bonding
and sealing to grow more relevant in the value chain and we are
currently addressing the next generation of challenges ahead ofthe need. While the landscape may change, and applications
may morph along with change, Sika’s constant focus is that oursolutions remain added value to our customers.

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