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MATERIALS TO ENABLE THE NEXT-GENERATION OF EV CHARGING INFRASTRUCTURE

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MATERIALS TO ENABLE THE NEXT-GENERATION OF EV CHARGING INFRASTRUCTURE

  1. 1. MAHMOUD AWWAD, NOVEMBER 2022 MATERIAL SOLUTIONS FOR EV CHARGING INFRASTRUCTURE
  2. 2. AGENDA 2 TOPICS 01 Introduction 02 Challenges / Expectations 03 Trends / Future 04 Materials Solutions 05 Conclusion
  3. 3. MAHMOUD AWWAD INTRODUCTION 3 Business Development Manager, Power Conversion & Industrial Automation, Henkel Industrial Adhesives ▪ With Henkel Adhesive Technologies since 2008 ▪ Based in Utrecht area, the Netherlands ▪ 15 years of serving customers in multiple markets including Industrial Automation, Power Conversion, Automotive, Medical and Power Electronics
  4. 4. €2.7BN ADJUSTED OPERATING PROFIT (EBIT) SALES €20.1BN WE ARE ACTIVE IN 79COUNTRIES 145YEARS SUCCESS WITH BRANDS AND TECHNOLOGIES AROUND 38% WOMEN IN MANAGEMENT -50% LESS CO2 EMISSIONS PER TON OF PRODUCT1 WE EMPLOY MORE THAN 52,000 PEOPLE WORLDWIDE FROM 124 NATIONALITIES 4 ¹ Figure relates to the 2021 fiscal year compared to the 2010 base year
  5. 5. CHALLENGES IN EV CHARGING INFRASTRUCTURE 5 Consumer Expectations SAFETY Critical and non-negotiable. Safety agencies ubiquitous. TOTAL COST OF OWNERSHIP Capital cost will be important as many units purchased by local utilities and consumers remain sensitive . RELIABILITY Available chargers expected to work. Harsh environments and public installations. Product life. CHARGING SPEED Customers expect to charge in short time. Destination charge is not always reasonable or desired ACCESIBILITY Until charging is abundantly available, across provider access and charger uptime is paramount
  6. 6. CONVERGENCE OF ENERGY & INTERNET Systems, Data, Optimization, and Security all lead to more computational and communications overhead HIGHER POWER As battery voltage and charge speed expectations increase, power will naturally follow TRENDS IN EV CHARGING INFRASTRUCTURE 6 Innovation and Future Needs HIGHER EFFICIENCY Legislation, Corporate Citizenship and TCO drive for more energy efficient solutions. INCREASED ENVIRONMENTAL AWARENESS Grid Citizenship, Legislation, Efficiency, Waste, and Reliability all play into this key trend STANDARDIZATION Important for accessibility, safety, and total cost of ownership. Drives an expected experience
  7. 7. 7 ▪ Result of – Higher charging speed – Increased function – Higher voltage – Higher current – Wide Band Gap ▪ Thermally conductive potting ▪ Thermal interface materials ▪ Solid insulating materials HIGHER POWER IN EV CHARGING
  8. 8. 8 ▪ Driven by: – Consumer anxiety – Harsh environments – Increased temperature – Outdoor exposure – Impact & vandalism – Temp cycles ▪ Gasketing & sealing solutions ▪ Conformal coating ▪ Connector potting ▪ Thermal interface solutions RELIABILTY IN EV CHARGING
  9. 9. HENKEL MATERIAL SOLUTIONS FOR EV CHARGERS 9 Overview Application Technology Level 1 Level 2 Level 3 / Ultra-fast Thermal Thermally Conductive Insulating Films (Sil Pad, Hi Flow) ✓ ✓ ✓ Gap Filling Materials (GAP PAD, Gap Filler) ✓ ✓ ✓ Phase Change ✓ ✓ ✓ Protecting Potting (charging guns) ✓ ✓ ✓ Conformal Coatings ✓ ✓ ✓ Gasketing / Sealing ✓ ✓ ✓ Bonding Thread Locking Adhesive ✓ ✓ ✓ Staking Adhesives ✓ ✓ ✓
  10. 10. CONTROLLING THERMAL CONDITIONS FOR DC FAST CHARGING RELIABILITY 10 CHALLENGES Phase change material on a power module system converter board SIL PAD material on a discrete component system converter board ▪ Building out a fast-charging EV infrastructure demands a return on investment via reliable systems that prioritize durability, performance and safety. ▪ A major concern with DC fast and ultra-fast chargers is their voltage levels that range from 400V to over 1000V and power that can be in excess of 350kW. ▪ To control the heat generated by such high-power transfer, system designers must employ highly-effective thermal management strategies to maintain consistent and reliable power delivery, both for the charger and the battery pack. SOLUTIONS
  11. 11. PROTECTING ELECTRONICS IN EV CHARGING DEVICES 11 CHALLENGES Applicable to EV chargers of all levels, especially those positioned outdoors, Henkel’s Sonderhoff formed-in-place-foam-gasket (FIPFG) technology provides a comprehensive equipment and high-reliability material combination. SOLUTIONS ▪ Because the chargers may require service, gasketing materials used to secure the housing structure should provide a tight seal to keep out dust, moisture and corrosion, while allowing access for serviceability. The gaskets need to offer long-term protection, withstand temperature fluctuations, cope with heat generated by electronic components, and resist degradation from outdoor exposure. ▪ High automation capability to facilitate high volumes (residential and commercial chargers), as well as manage large designs (DC fast charging stations) and various closure geometries will provide manufacturing flexibility, design modification adaptability and reduced production costs.
  12. 12. BUILDING DURABILITY INTO EV CHARGING CONNECTORS 12 CHALLENGES Henkel’s portfolio of UL-rated potting materials offers a range of formulations with different chemistry platforms, cure schedules and flexible pot life timelines. Proven in numerous applications, these materials are well-suited for the demands of EV charging connectors. SOLUTIONS ▪ To protect and strengthen the connector assembly, potting material is dispensed inside the charger handle, covering and encapsulating all of the cables and components, and adhering to the interior of the case. Strong adhesion to all surfaces – plastics, wire and component coatings -- is essential. ▪ To accommodate high-volume production speeds, the potting material should dispense and cure quickly, with no leakage so as to ensure ample material for protection of interior components. Balancing material viscosity with lower gel times is advantageous. ▪ UL 94 flammability certification for defense against fire from high thermal loads, as well as moisture and dust resistance for ingress protection, are key to meeting charger performance expectations.
  13. 13. CIRCUIT-BOARD PROTECTION FOR SYSTEM-LEVEL RELIABILITY 13 CHALLENGES Henkel conformal coatings ensure electronic operational integrity by defending electronic circuits from thermal shock, dust, moisture and dynamic environmental conditions. Simple to apply and process, these SVHC, solventless, tin-free formulas are UV and moisture cure capable for optimized sustainable protection SOLUTIONS ▪ As global electric vehicle (EV) volumes continue to grow, the need for reliable charging devices is front and center. ▪ Consumer satisfaction with the EV experience will largely be driven by cost, convenience and charging device reliability – both at home and on the road. ▪ For chargers of all power levels – from level 1 to level 3 - protecting the internal electronics from environmental contaminants helps keep them operating as expected.
  14. 14. SUSTAINABILITY IN EV CHARGING 14 Leading Driver for Adoption ▪ Primary driver for early consumers to adopt EV ▪ Sustainability is a valuable goal on its own merit, but also resonates with customers and shareholders ▪ Materials choices in designing and manufacturing charging solutions can have a significant impact on scope 1, 2, and 3 emissions
  15. 15. 15 HENKEL SOLUTIONS FOR EV CHARGING INFRASTRUCTURE AC charging versus DC charging On-board versus Off-board equipment
  16. 16. CONCLUSION 16 ▪ EV vehicles be comparable with fuel-based vehicles in terms of charging max. 10 mins ▪ Public charging stations will need to be installed rapidly to keep up with demand and multi-household infrastructure ▪ Ecosystems for EV infrastructure need to develop in order to support the grid resilience and ensure grid stability (energy storage could be a solution here) ▪ Comfort will play a critical role for further EV adaption - range anxiety changed into charge point and charge time anxiety
  17. 17. THANK YOU. 17

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