Despite the impressive progress made in lithium ion energy storage, the challenges faced by battery systems remain significant in terms of energy densities, cost optimization, improved safety performance and durable life cycle. Our goal is to develop cutting-edge solutions for next generation vehicles. Our solutions help to optimize performance and improve the battery energy density, duration, weight reduction and recharging time. Our market-leading portfolio of battery solutions cover applications inside and outside the cell, from cell to module and battery pack assembly up to battery system integration into the vehicle.
Inside and outside the cell, we have the market leading technology portfolio of specialty materials for battery systems that increase efficiency, safety and reliability
Internal battery cell applications
The battery cell is a key component where chemical energy is converted to electrical energy. The cell contains an anode, cathode, electrolyte and a separator. The particles of the active material are held together with a special binder. The electrons flow from anode to cathode through an external circuit, while ions move from anode to cathode through electrolyte. When a battery is connected to an external circuit, chemical reactions occur to generate the energy.
Our solutions help to optimize the chemical reactions inside the cell to boost the battery performance in terms of charging time, prolonged lifecycle and high energy density.
Separator membrane coatings
The separator is an electrically insulated membrane placed between the anode and the cathode. It enables the exchange of lithium ions from the anode to cathode in the charging process, and in reverse during the discharging process. To improve the cell assembly process and/or to improve the overall cell performance, special coatings can be applied to each side of the separator. Kynar Flex®LBG series has been specifically designed for this application; it brings superior adhesion to the electrodes and high dimensional stability to the assembly under high voltage conditions. Kynar® PVDF resins have become the reference for use in lithium-ion cells due to its extreme performance.
Although the binder represents only a fraction of the battery weight and cost, the Kynar® PVDF binder is fundamental during the electrode manufacturing process. Its design is key to ensure fast dissolution, high slurry content and fast casting. Or looking further allowing greener and more sustainable manufacturing processes. Although characterized as an inactive material, the Kynar® PVDF binder is an extremely active material during battery cycling. It manages volume variations and side reactions of high energy density active materials which helps to maintain a firm structure of electrodes. The Kynar® PVDF HSV series are well known for their success in this highly demanding application.
Ultra-pure lithium electrolyte salts
Electrolytes ensure the flow of lithium ions within the battery, which is directly linked to battery lifecycle. To guarantee long-term performance, electrolytes can be improved using Foranext® electrolyte salts.
LiFSI has the highest ionic conductivity among all lithium salts. Its remarkable electrochemical (>5V) and thermal stability make it an ideal choice to be used as a main salt or additive.
LiTDI is an additive that helps to increase battery life, due to several properties:
- Solid Electrolyte Interface (SEI) stabilization
- HF and water scavenging
- Aluminum current collector passivation.
We can provide expert support for electrolyte solutions for lithium battery development and we are ready to discuss your projects.
Multi-walled CNT as conductive additive
Graphistrength® multi-wall carbon nanotubes (MWCNT) are a highlight of Arkema’s development in nanomaterial technology and are the conductive additive of choice for high-performance electrodes. Indeed, electrical conductivity is key in the development of high energy density and efficient charge or discharge of the lithium ion batteries. Graphistrength®-containing composite electrode materials- achieve better electromechanical performance by providing an efficient electrically conductive network in battery electrodes.
Graphistrength® MWCNT is the cutting-edge solution to improve the lifecycle of next generation electric vehicles. Graphistrength® MWCNT is versatile and adaptable to different needs such as lithium cell geometry as well as the manufacturing process of the electrodes. Our team helps customize MWCNT in dispersions based on different solvents for different specification requirements.
Cell to module assembly
The module is a component of the Hybrid Electric Vehicles (HEV) and Battery Electric Vehicles (BEV) that holds together a group of battery cells.
Module assembly plays a key role in protecting the cells from shock and vibration that occurs during vehicle operation.
Battery module architecture is crucial for battery system thermal management; therefore, it can incorporate heating, cooling or heat exchange systems.
Bostik smart adhesives provide a large portfolio of solutions covering bonding, cell-to-cell and cell-to module assembly and encapsulation. Whether pouch, prismatic or cylindrical, we cover all cell type assemblies for modules to provide mechanical integrity between the cells and ensure their safety and reliability as well as thermal management. Our solutions are designed to protect battery cells and modules from moisture intrusion, various chemical fluid leaks and exposure to the outside environment.
- Easy-to-process and solvent free sprayable adhesive solutions (pressure sensitive and waterborne adhesives) for pouch cell-assembly
- Tailor-made 2K polyurethane adhesive materials for prismatic cells module assembly
- Best-in-class MMA based adhesives predestined for cylindrical module bonding with an optimal balance of key properties
- Hot melt polyamide adhesives for encapsulation applications, bolstered by our leading position in specialty hot melt adhesives
- Thermal conductive adhesives if, in addition, heat transfer and thermal management is required
Battery pack sealing and enclosure
Sealants play a crucial role in battery pack enclosures to protect the battery from exposure to elements that might affect its performance.
Bostik smart sealants are lightweight solutions that help to reduce the weight of battery systems which are often heavy and take up space on the vehicle floor. Bostik smart sealants are ideal for battery pack assembly and are tailor-made to address the needs for removability and adaptability to high-speed manufacturing processes for automotive OEM's. To assemble the pack, adhesion to different substrates is key because the battery pack is made from various metals or composite materials. Our comprehensive portfolio of sealants combined with our expertise in the automotive industry provide the right solution for our clients.
Our battery pack sealants and adhesives contribute to improved battery system lifespan by providing protection thanks to:
- Extreme flexibility
- Excellent durability
- Excellent sealing performance and air tightness
- Serviceability or removability for post repair
- Excellent adhesion with limited surface treatment
- Rapid and precise application enabling high speed automated manufacturing.
Our battery pack sealants and adhesive solutions portfolio contains:
- Battery pack sealing and gasketing: SMP (Silyl Modified Polymers), Butyl, HMPSA (hot melt pressure sensitive adhesives), Synthetic rubber, CIPG/UVFG
- Structural bonding battery pack: MMA (methyl methacrylate), Instant adhesive (2K Cyanoacrylates), 2K-PU (polyurethane).
The battery pack and enclosure are subject to extreme environmental conditions such as vibrations and shocks that can eventually affect the battery lifespan. Battery pack application materials require superior mechanical properties and high durability to protect the battery’s function. Often in vehicle energy storage systems, the non-energy storing components take up a large space and add to the overall weight. Therefore, advanced thermoplastic composites are key for lightweight structural storages development in next generation BEV and HEV vehicles.
Elium® is the first thermoplastic resin designed for manufacturing composite parts with high performing mechanical properties. Elium® is a game changing resin that helps solve the challenges that the automotive industry faces:
- Lightweight: 30% to 50% lighter than identical parts made out of steel
- Mechanical properties: while being lighter than metal provides the same level of resistance
- Recyclability: possibility to recycle via de-polymerization.
Encapsulating case coating
EV batteries are subject to possible damage from external bodies, such as stone chipping du to their location on the bottom of the vehicle, near the rear wheel. Material requirements for encapsulating cases include mechanical resistance, corrosion resistance as well as insulation properties in order to ensure battery lifespan longevity.
Our Rilsan® Fine Powder high performance solutions are the material of choice for battery metal case coatings. Rilsan® Fine Powders are bio-based thermoplastics made from castor plants suited for extreme condition applications requiring high resistance and durability. Their key properties specific to coating applications are excellent resistance to damage (such as stone chipping), excellent corrosion resistance, high insulation properties and low coating thickness (<200 µm).
Battery management systems
Battery management systems (BMS) are an electronic systems built with the battery pack.
BMS monitor the state of the battery for various performances such as voltage, temperature, charge status and safety. We offer cutting-edge solutions to address the most critical challenges to help improve battery management systems.
From piezoelectric polymers for sensors and high performance thermoplastic coatings to hot melt polyamides for encapsulation and low pressure molding applications, our offer for battery management systems is designed to enable effective power distribution and improved battery lifetime.
Piezoelectric polymers for sensors
Lithium ion batteries are prone to gradual capacity fade due to electrochemical processes such as active material dissolution, electrode particle cracking or electrode adhesion degradation. Battery state of health (SOH) is a critical measurement for the reliable and durable operation of lithium ion batteries.
We developed a revolutionary piezoelectric polymer for efficient battery cell monitoring through non-invasive acoustic and ultrasound measurement. P(VDF-TrFE) piezoelectric copolymers, Piezotech® FC, are very sensitive to acoustic waves and ultrasounds. Due to their sensibility, when integrated into a battery, data can be collected to help improve battery lifetime and management.
Battery busbar coating
BEV and HEV applications require highly resistant material to guarantee sustainable and durable vehicle operation. One key component of the battery system is the busbar. Busbars combine a system of electrical conductors, which collect and distributes electrics current to power vehicle subsystems. This power distribution component consists of copper or aluminum conductors and an insulated coating for high-temperature applications.
Our bio-based Rilsan® PA11 coatings meet all the requirements needed for the extreme performance challenges of busbar applications. Rilsan® PA11 coatings provide exceptional abrasion resistance as well as thermal and chemical resistance.
Encapsulation & Low Pressure Molding of electronic components
Electronic components such as sensors and critical connector interfaces require durable and waterproof solutions with suitable mechanical and thermal properties, which address flammability concerns as well.
Our Thermelt™ Hot Melt Polyamides and Born2Bond™ engineering adhesives such as UV Cyanoacrylates are perfectly adapted for encapsulation and protection of these critical components. In the Low Pressure Molding (LPM) applications, our moldable hot melt polyamides offer a durable and bio-based solution, with increased production efficiency and unmatched opportunities for material design. For conformal coating applications, our low-odor, low-blooming and dual curing cyanoacrylate adhesives offer rapid bonding through transparent parts as well as effective cure between opaque substrates.
With our global R&D and technical support, we strive to provide you with the right solution for the protection of critical electronic components:
Hot melt polyamide for encapsulation and low pressure molding (LPM) applications bolstered by our leading position in specialty hot melt adhesives
Encapsulation: hot melt polyamides, engineering adhesives, UV acrylics
- Encapsulation for electronic components (sensors, connectors)
- Encapsulation and protection of critical connector interfaces.