Tim Qian Henkel Corporation

1. 1
High Performance Thermal Interface Materials
for EV Battery Thermal Management
Tim Qian, PhD
Principal Scientist
Battery Tech USA, March 7th, 2023

2. SALES
€20.1BN
146YEARS
SUCCESS WITH
BRANDS AND
TECHNOLOGIES
-50%
LESS CO2 EMISSIONS PER
TON OF PRODUCT1
WE EMPLOY MORE THAN
52,000
PEOPLE WORLDWIDE
FROM 124 NATIONALITIES
in 79 COUNTRIES
2
¹ Compared to the base year 2010
ADHESIVE TECHNOLOGIES CONSUMER BRANDS
AROUND
38%WOMEN IN
MANAGEMENT

3. 3
AUTOMOTIVE COMPONENTS BUSINESS
GLOBAL INNOVATION FOOTPRINT
8 Innovation
Hubs
Automotive Expertise
~200
Scientists
Multi-
Technologies
~50 Thermal
& Battery
Solutions Experts
~400*
Patents
Automotive
Applications
* Active patent families
+200M€
Invest
Düsseldorf/Shanghai/
Madison Heights
Detroit/Madison
Heights, USA
Düsseldorf, Germany
Seoul, Korea
Shanghai, China
Yokohama/Isogo, Japan
Chanhassen, USA
Pune, India
LATAM Hub
Global key
account
management
network
Global
production
network

4. ▪ Battery Cell
▪ Battery Module
▪ Battery Pack
▪ Battery Control Module
▪ 48 V for Mild Hybrid
▪ Inverter
▪ Onboard charger
▪ DC/DC Converter
▪ Electric Motor
▪ Electric Transmission
▪ Electric Drive Housing
ESTABLISHED MATERIAL PARTNER FOR ELECTRIC VEHICLES
4
Battery System Power Conversion System Electric Drive System
Henkel has broad technology portfolio to increase efficiency, safety and reliability of EV
Thermal Interface
Materials
7
Battery Cell
Adhesives
6
Functional
Coatings
5
Metal
Pretreatment
4
Gasketing
8
Structural &
Assembly Adhesives
1
Compression
Pads
2
Thermal Propagation
Prevention
3
(Thermal) Potting
2
Gap Pad
1
Gap Filler
3
Gasketing
4
Magnet Bonding
2
Thermal Potting
3
Gasketing
4
Impregnation Service
1

5. HENKEL’S E-MOBILITY SOLUTIONS
5
Key Battery Applications
APPLICABLE TO VARIOUS
BATTERY TYPES
Pouch
Cylindrical
Prismatic
Structural Adhesives
for the Battery Pack
Fire Protective Pad
2
6
Gasketing of
Battery Pack Housing
Thermal Propagation
Prevenetion
Battery Cell
Assembly Adhesives
3
4
5
Dielectric Coating
1
Thermal Gap Filler
8
Thermally Conductive
Adhesives
7

6. 6
THERMAL MANAGEMENT IS CRITICAL FOR EV BATTERY
▪ Conformable to displace air gaps
▪ Carry heat away
▪ Stress relief from thermal cycling
▪ Stable over time and operating
conditions
Optimal operating temperature
15-35°C
Material
Thermal
Conductivity
(W/m-K)
Air 0.025
Polymers 0.2
Al2O3 30
Al (OH)3 25
AlN 175
Aluminum 200
BN 30-600
SiC 100-200
Graphite 120-165
TIM: polymer-filler composite

7. 7
THERMAL MATERIALS: PHYSICAL FORMS
Pads Liquids
large volume, low
cost, high throughput
application

8. 8
THERMAL MATERIALS: LIQUID TIM DISPENSING
Henkel works with all the major dispensing partners:
After assembly
Cure in place
▪ No cut-out waste

9. 9
THERMAL MATERIAL: CHEMISTRY TYPES
Cure
Schedule
Cured
Modulus
Durability
Low MW
Migration
Temp.
Stability
Adhesion
Resin /
Matrix
▪ Resin/Matrix influences physical and adhesion properties of thermal materials

10. 10
MODULE-TO-PACK VS CELL-TO-PACK
Prismatic
▪ Potentially less weight and better volume integration
▪ reduction in parts and assembly steps
▪ Reduce cost
▪ Increase energy density
Battery cells are directly integrated into the pack
without module structure
Module and pack components are successively
improved with regards to mass, volume utilization, etc.
▪ Reliable, each components optimized individually
▪ Repairable/replaceable based on individual module
▪ Easy management by BMS, good serviceability

11. 11
MODULE-TO-PACK VS CELL-TO-PACK
Prismatic
Battery cells are directly integrated into the pack
without module structure
Module and pack components are successively
improved with regards to mass, volume utilization, etc.
𝑅𝑡𝑜𝑡𝑎𝑙 (𝑚−𝑝) > 𝑅𝑡𝑜𝑡𝑎𝑙 (𝑐−𝑝)
𝑅𝑡𝑜𝑡𝑎𝑙(𝑚−𝑝) = 2𝑥𝑅𝑖𝑛𝑡−1 +𝑅𝑡𝑖𝑚−1 + 𝑅𝑚𝑜𝑑.𝑐𝑎𝑠𝑒+ 2𝑥𝑅𝑖𝑛𝑡−2 +𝑅𝑡𝑖𝑚−2 𝑅𝑡𝑜𝑡𝑎𝑙(𝑐−𝑝) = 2𝑥𝑅𝑖𝑛𝑡−1 +𝑅𝑡𝑖𝑚−1
cell
tim-1
tim-2
cooling
module case
cell
tim-1
cooling
Interface-1
Interfacial -2
Thermal impedance
TIM: thermally conductive
adhesives (TCA)
TIM: thermal gap fillers (TGF)

12. 12
PROPERTY COMPARISON: TGF VS TCA
Characteristic Method TGF 2010APS TLB 9220APS
Thermal
Conductivity
ASTM D5470 2 W/mK 2 W/mK
Density ASTM D792 2.0 g/cc 2.7 g/cc
Viscosity Rheometer (25°C for
1s-1, 35°C for 1500 and
3000 s-1)
~350 Pa*s@1s-1;
~10 Pa*s@1500s-1;
~7 Pa*s@3000s-1
~400 Pa*s@1s-1;
~50 Pa*s@200s-1;
~45 Pa*s@1500s-1
Dispensing rate Internal setup, 90psi ~250 cc/min ~40 cc/min
Compression force Internal setup,
200mm/min, 5cc
~120 N ~450 N
Hardness ASTM D2240 Shore oo 65 Shore D 65
Adhesion (lapshear) Al to Al 0.25 MPa 8-10 MPa
Adhesion (180° Peel) Metalized pouch to Al 0.02 N/mm 1 N/mm
Flow: TGF>TCA
Hardness: TGF<<TCA
Adhesion: TGF<<TCA

13. ▪ Enabling existing and new Battery
Module to pack Designs with efficient
thermal management
▪ Excellent high dispense rates up to 80
ccm/ sec
▪ Cost efficiencies due to automated
dispensing and short application times
▪ Room Temperature cure system / easy
mixing ratio of 1:1
▪ Enabling fast charging and longer
driving range due to efficient thermal
management
▪ Low hardness accommodate larger gap
with high tolerance
THERMALLY CONDUCTIVE GAPFILLER
13
For Battery Modules and Pack Designs
Technology Introduction Features & Benefits
Wide range of SMP and Silicone technologies with mid to high thermal
conductivity, fast dispense rates and easy re-work
Key Parameters
BERGQUIST
TGF 2010APS
BERGQUIST
TGF 2025 APS
BERGQUIST
TGF 2200 APS
BERGQUIST
TGF 3010 APS
Chemistry 2K SMP 2k SMP 2k Silicone 2k SMP
Thermal
Conductivity
2,2 W/mK 2.1 W/mK 2,2 W/mK 3.0 W/mK
Density 2.0 g/cm³ 1.94 g/cm³ 2.06 g/cm³ 3.1 g/cm³
Open Time 7.5 h @ 25°C 7d @ 25°C 24 h @ 25℃ 4 h @ 25℃
Attributes
high dispense
rate, low
abrasion
characteristics
Ultra low
compression
rate, fast
dispense rate
Low volatile SI
base, moderate
dispensing
Ultra fast low
compression
rate, high
thermal
performance

14. ▪ Enabling new cell-to-pack designs with
efficient thermal management
▪ Excellent shear strength and elongation
performance
▪ Cost efficiencies due to automated
dispensing and short application times
▪ Room Temperature cure system / easy
mixing ration of 1:1
▪ Enabling fast charging and longer
driving range due to efficient thermal
management
▪ Minimize thermal interface thickness
with good adhesion to cell structure
THERMALLY CONDUCTIVE ADHESIVES
14
For Battery Modules and New Pack Designs
Technology Introduction Features & Benefits
Wide range of Epoxy and PU technologies with multi-function properties of
thermal conductivity, elongation and mechanical strength
Key Parameters
LOCTITE
EA 9497
LOCTITE
TLB 9150 APS
LOCTITE
TLB 9200/9220
APS
LOCTITE
TLB 9300 APS
Chemistry 2K Epoxy 2k PU 2K PU 2K PU
Thermal
Conductivity
1.4 W/m-K 1.2 W/mK >2.0 W/m-K 3.0 W/m-K
Density 2.07 g/cm³ 1.87 g/cm³ 2.50 g/cm³ 2.96 g/cm³
Open Time 165 min @ 25℃ > 40 min @ 25°C 30 min @ 25℃ 20 min @ 25℃
Lap Shear strength
Al / Al
≥ 7 MPa
Al / Al
10 MPa
Al (6061)/Al
(3003)
≥ 8 MPa
Al 6063 + Al
6063
≥ 3.0 MPa

15. FUTURE MATERIAL INNOVATION TO ENABLE REPAIR
15
▪ Battery modules removable with gap filler, but
not if bonded with TCA
▪ Right-to-repair demands removable and
replaceable battery (current 25kg limit)
▪ Sustainability calls for reusable or repairable
battery
▪ Need to collaborate and innovate
– Debonding technology
– Change in material scope and requirement
Gap filler, low adhesion
https://youtu.be/Qi8Y2lF7Luw
VW battery module
removal before
recycling

16. NEW WAY OF APPLYING MATERIAL: INJECTION
16
▪ Process advantage
– High-throughput
– Inject directly into assembly
– Separation of module assembly from
chemical handling
– Reduced footprint
▪ Material requirement
– Ready-to-flow at low pressure
– Good substrate wetting
– Stable for short term storage
– Remixable
Injection of curable thermal material

17. 17
Key Takeaways
High-speed production, lowering costs
Future innovation needed for sustainability
and advanced battery design
TIM selection based on material characteristics
and specific battery design
Thermal management is critical to EV battery and
liquid material is preferrable
17

18. 18
THANK YOU!
Driving the future.
Tim Qian, Product Development
Tim.Qian@Henkel.com
Pradyumna Goli, Business Development Manager
pradyumna.goli@henkel.com