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Battery Solutions

Low Maintenance Sealants

There are a number of products available at your local hardware or home improvement store, including those with 20 year warranties, that need annual maintenance or replacement.

Innostar brand sealants do not require annual maintenance and are designed for decades of reliability in harsh environments. 

HOW SEALANTS ARE USED IN Batteries

Liquid adhesive solutions play a crucial role in the manufacturing and assembly of electric vehicle (EV) batteries.  Adhesives are used for various applications to ensure the requirements for structural integrity, thermal management, and overall performance of the battery pack are met.  Advantages of using liquid adhesives can include discreet placement, automation capability, shock & vibration management, thermal management, sealing and bonding in one step, joining of dissimilar materials, compensation for thermal expansion, and weight reduction.

Bonding:

  • Cell Bonding: Adhesives bond individual battery cells together to form a module or pack, ensuring mechanical stability and uniform thermal stress distribution.
  • Module Assembly: Adhesives secure battery cells within a module, providing structural integrity and preventing movement or vibration.
     

Sealing:

  • Battery Pack Encapsulation: Adhesives seal and encapsulate the entire battery pack, protecting against environmental factors like moisture and contaminants.
  • Lid and Case Sealing: Adhesives seal the battery pack’s casing and lid, preventing moisture ingress while maintaining structural integrity.

Thermal Management:

  • Thermal Management: Traditional Thermal Interface Materials (TIMs) are conductively filled silicones, greases, waxes or pressure sensitive adhesives that add none to modest mechanical strength.  InnoStar offers typical thermal interface materials such as gap-pads, silicone films, phase change materials, thermal gels, and fill structural adhesives.
  • Thermal Insulation:  Typically, most adhesives are thermally and electrically insulative, unless a conductive filler is added.
  • Busbar Attachment: Adhesives secure electrical busbars to battery cells, ensuring reliable electrical connections and efficient current flow.
     

Reinforcement:

  • Battery Module Reinforcement: Adhesives reinforce critical joints and connections within the battery module, enhancing mechanical strength and durability.
  • Wire and Cable Bonding: Adhesives secure and insulate wiring and cables within the battery pack, preventing wear and ensuring proper electrical connectivity.
     

Safety:

  • Sensor and Electronics Attachment: Adhesives secure sensors, control electronics, and other components within the battery pack.
  • Battery Insulation: Adhesives apply insulation materials within the battery pack to prevent short circuits and ensure the safety of electrical components.
  • Vibration Damping: Adhesives with viscoelastic properties minimize vibrations and reduce the risk of mechanical fatigue in battery components.
  • Safety Features: Adhesives may be used in the construction of safety features, such as impact-absorbing structures, to enhance the battery pack’s ability to withstand accidents and impacts.
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