Light-Curable Materials for Electric Vehicle Batteries

EV Battery Systems

E-Mobility - Electric Vehicle Battery Systems

Design Battery Packs with Reliable Performance

The Battery Show 2019
Protecting electric vehicle battery systems from harsh environments is critical, as e-mobility designs of full electric and hybrid electric vehicles continues to gain traction. The battery is the heart of an electric vehicle and must maintain performance under drastic temperature changes and corrosive elements like salt and sulfur, as well as moisture, vibration, and shock.

To ensure top performance, functionality, and long service life of hybrid and EV batteries, components must be bonded, sealed, potted, or coated. Dymax light-curable materials are suitable for applications using cylindrical, pouch, or prismatic lithium-ion battery designs, as well as applications involving electrical components inside charging stations.

Our light-curable materials cure in seconds for faster processing and higher throughput and are available with many innovative and patented technologies that turn problems like shadow areas, cure confirmation, and difficult inspection into non-issues. Our materials are also solvent free and one-part, requiring no mixing or prep before application. Most products are available in multiple viscosity grades so the material flow can be tailored to the individual application. IPC approved, MIL-I-46058C, and UL listed self-extinguishing grades are available.

Available Light-Curable Materials

Conformal Coatings

Dymax light-cure conformal coatings help protect printed circuit boards in battery management systems (BMS) and charging stations from thermal shock and humidity, and corrosive elements like salt and sulfur. Formulations are available with fluorescing technology, in IPC-CC-830 approved, MIL-I-46058 listed, and UL recognized grades, and with moisture-cure or secondary heat-cure capability.

Potting Materials

We provide potting materials that have excellent bond strength to both plastics and metals. They also provide excellent resistance to chemicals and thermal shock, making them a great choice for fixturing battery cells to the base.

Encapsulants

Dymax encapsulants protect critical electronic components throughout the electric vehicle battery system. Standard grades cure in seconds with UV/Visible light, but secondary moisture cure grades are also available for applications where shadow areas are a problem.

Form-in-Place Gaskets

Dymax gasket materials act as a barrier to prevent absorption or penetration of air, dust, noise, liquids, gaseous substances, or dirt for sound dampening, vibration dampening, moisture protection, chemical protection, and air sealing. These gaskets conform to complex and intricate channels, on both vertical and horizontal surfaces, and cure in place upon exposure to light.

Applications:
Conformal coating

Features:
Halogen-free
Solvent free
UV/Visible light cure in seconds
Secondary heat cure for shadowed areas
Blue fluorescing
Isocyanate free
Low VOCs
One part, no mixing required
Suitable for most types of spray equipment
Medium viscosity, designed to enhance wetting of leads
Low modulus for thermal cycling performance
MIL-I-46058C listed
IPC-CC-830-B approved
UL recognized

 

Applications:
Flex circuit bonding/attachment
Chip-on-flex
Chip-on-board

Features:
Halogen-free
UV/Visible light cure
One part, no mixing is required
Low VOC
Solvent free, Isocyanate free
Thixotropic for precise dispensing on ICs
Highly moisture resistant
Low dielectric constant for high frequency applications
Low modulus for minimal stress
Remains flexible at low temperatures

 

Applications:
Chip-on-board
Chip-on-flex
Chip-on-glass
Wire bonding
Recommended surfaces include FR4, Kapton, Glass

Features:
UV light cure
Secondary moisture cure capability
Flelxible encapsulant
Shadowed area performance

 

Applications:
Chip-on-glass
Chip-on-flex
Chip-on-board
Wire bonding

Features:
Halogen-free
UV/Visible light cure
Secondary heat cure
Blue fluorescing
Moisture and thermal resistance
Thixotropic for precise dispensing
Flexible

 

Applications:
Conformal coating
Thin protective black coating
Tamper-evident coating
Recommended substrates include FR4, glass, stainless steel

Features:
UV/Visible light cure in seconds
Secondary heat cure for shadowed areas
True black conformal coating
Uniform matte finish
ULVO flammability
Designed for thin coatings
One-part coating – no mixing required
Covers sensitive information
Can be coated in multiple passes
Optimized for single pass coating up to 0.004″
Can be coated thicker in multiple passes

 

Applications:
Conformal coating

Features:
UV/Visible light cure in seconds
Secondary moisture cure for shadowed areas
Halogen-free
Solvent free
One part, no mixing required
Bright blue fluorescing
Low viscosity for thin coatings
Chemically resistant
Low VOC
Low odor
MIL-I-46058C listed
IPC-CC-830B
UL 94 V-0
UL 746-E

 

Applications:
Conformal coating
Recommended substrates include lead frame, PCB, flex, silicone, and ceramic

Features:
UV/Visible light cure in seconds
Secondary moisture cure for shadowed areas
Excellent thermal shock resistance
Solvent free
One part, no mixing required
Bright blue fluorescing
Superior re-workability
Chemically resistant
Fast tack-free cure
Low surface tension
Halogen free

 

Applications:
Conformal coating
Recommended substrates include lead frame, PCB, flex, and ceramic

Features:
UV/Visible light cure in seconds
Secondary moisture cure for shadowed areas
Excellent thermal shock resistance
High temperature flexibility
Excellent chemical and corrosion resistance
Good temperature/humidity (85/85) performance
Solvent free
One part, no mixing required
Bright blue fluorescing
Fast tack-free cure
Halogen Free

 

Applications:
Conformal coating

Features:
Halogen-free
Solvent free
Light cure in seconds
Secondary heat cure for shadow areas
Isocyanate free
One part, no mixing required
Low viscosity for thin coatings
Rigid for chemical and abrasion resistance
MIL-I-46058C listed
IPC-CC-830-B approved
UL recognized