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Battery Pack Assembly

Enabling higher density and lower cost

The market for plug-in hybrid and battery-powered electric vehicles (EVs) is poised for growth. To successfully scale and take first-mover advantage, OEMs and their suppliers are turning to silicone solutions for light-weight, energy dense battery packs that resist overheating and are compatible with large-volume automated assembly systems.

Why silicones?

Silicones provide lightweight protection, excellent thermal stability and thermal event isolation for automotive battery modules of all types. Silicones can also be formulated to avoid slump and hold their shape when dispensed on vertical surfaces, ensuring that modules move efficiently forward on the production line.

Which silicones?

Dow offers a wide range of thermal interface materials, including:

Thermal gap fillers to deliver rapid processing, repairability and effectively dissipate heat from critical automotive parts, helping achieve reliability in a cost effective way. Dow’s broad product line also extends to polyurethane gap fillers.

Thermally conductive silicone gels and encapsulants for a “custom-fit” conformable gap filler around battery packs to shield them from mechanical, moisture, and temperature fluctuations.

Thermally conductive silicone adhesives for coupling the battery pack to the heat sink; also may be appropriate for use within or between cells to provide protection against excessive heat and cold. Use to insulate or help dissipate heat to ensure optimal operating temperatures.

Non-curing thermally conductive silicone compounds with a possible applied temperature range of -40 to 150°C for conducting heat in ADAS modules.

Dow offers further silicone materials for battery packs, including:

Silicone foams are ideal as compression gaskets that protect against water, dust and moisture. Silicone foams can also provide protection for battery cells during a thermal event.

Silicone adhesives for lid sealing and adhering components in a battery pack.

EMI materials

Conformal coatings to protect PCBs in battery management systems from the environment.

Battery module cell assembly and protection video

Protection against thermal runaway