EV Batteries

Battery packs

Potting, gasketing and assembling

Room temperature and Heat cure

Battery packs

Electric Vehicle (EV) battery packs are the heart of an electric vehicle, providing the energy needed to power the vehicle's electric motor. An EV battery pack is a collection of individual batteries, or cells, that are combined in a specific configuration to create a high-capacity energy storage system. The battery pack is a key component of the vehicle's powertrain and is responsible for storing and delivering energy to the electric motor.

The primary considerations in designing an EV battery pack are energy density, power density, and cycle life. Energy density is a measure of the amount of energy stored in a given volume, and it determines the overall range of the vehicle. Power density is a measure of the ability of the battery to deliver power quickly, and it determines the vehicle's acceleration and performance. Cycle life is a measure of the number of charge/discharge cycles the battery can endure before it reaches its end-of-life.

EV battery packs can be designed to use either lithium-ion or nickel-metal Hydride (NiMH) batteries. Lithium-ion batteries are widely used due to their high energy density, low self-discharge rate, and good cycle life. NiMH batteries are also popular due to their high energy density and low self-discharge rate, but they tend to have a shorter cycle life compared to lithium-ion batteries.

An EV battery pack must also be designed to be safe, reliable, and durable. This requires careful attention to the battery pack's cooling, protection, and management systems. The battery pack must be able to withstand the rigors of daily use and the extreme temperatures encountered during vehicle operation.


Thermal management of Battery packs

Thermal management is a critical aspect of electric vehicle (EV) battery pack design. The battery pack is a heat-generating component and must be cooled effectively to ensure safe and reliable operation.

The main functions of thermal management in an EV battery pack include:

  1. Regulating battery temperature: The temperature of the battery pack must be kept within a specific range to ensure optimal performance and safety. The battery's performance can be severely impacted by high temperatures, which can lead to reduced capacity, increased self-discharge, and even thermal runaway.

  2. Dissipating heat: The heat generated by the battery pack must be efficiently dissipated to prevent the temperature from rising to dangerous levels. This can be done through a combination of passive and active cooling methods. Passive cooling methods include heat sinks, thermal conduction, and convection, while active cooling methods involve the use of cooling fluids, fans, or other cooling systems.

  3. Protecting the battery from extreme temperatures: The battery pack must be protected from extreme temperatures, both hot and cold, which can damage the battery cells and reduce their life.

  4. Improving battery performance: Effective thermal management can improve the performance of the battery pack, by increasing the energy density and power density of the battery, and by reducing the self-discharge rate.

The thermal management system of an EV battery pack is a complex and interdisciplinary system that involves a combination of mechanical, electrical, and materials science. Effective thermal management requires a deep understanding of the heat transfer mechanisms within the battery pack and the use of advanced computational tools to design and optimize the system.

In conclusion, thermal management is a critical aspect of electric vehicle battery pack design. The main functions of thermal management in an EV battery pack include regulating battery temperature, dissipating heat, protecting the battery from extreme temperatures, and improving battery performance. Effective thermal management is essential to ensure the safety, reliability, and performance of the battery pack.


Battery pack encapsulation

Encapsulation is one of the main concerns for Lithium-Ion Batteries of electric cars. The encapsulant that is potted within/around the batteries needs to be specially designed as a room temperature curing potting material. Preferably it is of silicone chemistry with thermally conductive fillers that allow low viscosity & low specific gravity. Its critical role in the vehicle's operation dictates that it should meet UL94 V-0 flammability rating and  it also needs to self-level for pouring over/injection over applications. 

The product must be easy to mix and pour or inject so that it can be used for high volume manufacturing. It should also prevent the PCB and electronic components from environmental corrosion, dust, moisture, mechanical damage and help reduce shock and vibration. Ideally it should keep robust performance in heat dissipation, mechanic and electrical insulation under extreme conditions of temperature and humidity.

Material requirements

  • Sufficient thermal conductivity (> 1 W/mK)
  • Electrical Insulation with high dielectric strength
  • Self-leveling for void-free encapsulation
  • Low viscosity to aid the component encapsulation
  • Low compression stress during assembly

Application requirements

  • Light weight with low specific gravity
  • Long-term reliability
  • Stable performance in automotive environment (temp, solvent and humidity)

Processing requirements

  • Suitable for high volume manufacture
  • Easy and fast to apply
  • Cost-effective and reworkable





Low viscosity 
is required to accomodate the encapsulation

Low density is required to keep the weight of the battery pack low.

Low shrinkage and modulus are required to reduce the curing stress on components.

Our suggestion for a silicone, room temperature cure potting product that can cover all of the above is the newly formulated Honeywell's HLT1000P. Go to the product page or contact us with your application requirements for more information.

Base plate cooling

Gap fillers Applicable

Thermal Hybrid: Offer >3.5W/mK thermal conductivity and good long-term reliability; dispensable for automated process.

Thermal Gap Pad: Ultra-high compressibility enables low stress and excellent conformity to mating surfaces with good thermal performance. Honeywell TGP exhibits minimal bleeding and maintain effective performance through reliability testing.