Battery Packs and Cell Contacting Systems

E-mobility is the future of transportation. Hybrid and electric vehicles require efficient state-of-the-art energy storage systems. A key technology here are high-performance cell contacting systems (CCS), which connect the individual lithium-ion battery cells mounted on the plastic carrier boards that are then assembled into a complete battery system.

As batteries for electric cars have to work up into the high-voltage range, they must be assembled from hundreds of individual lithium-ion batteries while still fulfilling stringent performance, durability and safety criteria. Panacol adhesives ensure on one hand loss-free energy transmission, and on the hand they are flexible enough to compensate for the different thermal expansion rates of the materials used within the connecting elements. 

Welded copper tracks on battery packs and strands to flexible conductors create surfaces that are prone to corrosion. Panacol has developed special UV adhesives with a low ion content that protect these welds from corrosion as well as providing mechanical support and compensating thermal expansion of the different materials. Specially developed UV glob tops and UV coatings offer flexible solutions for a wide range of CCS layouts and geometries. 

For connecting and sealing welded joints on cell contacting systems and battery packs that contain shaded areas that the UV light cannot reach, Panacol has developed special moisture-postcuring UV acrylates. Here, most of the adhesive is cured with UV light and its structure is polymerized, while residual monomers in the shaded area that remain uncured subsequently cross-link through air humidity. Full curing is therefore also achieved without additional crosslinking in the oven, thereby protecting the carrier board from unwanted heat exposure. 

In many battery packs the control electronics are already integrated, so that the charge level and heat development in the battery pack can be continually monitored. For sensors Panacol provides specially formulated adhesives.

Adhesives for cell contact systems and battery production

Welding points of cell contacting systems are covered with ionically pure adhesive to prevent corrosion (click to enlarge)

In the following table you will find a selection of adhesives suitable for the protection of welded joints and the encapsulation of battery packs and cell contacting systems. We would be pleased to advise you on our products and their application. Other products and customer-specific solutions are available on request. 

Technical data sheets can be downloaded by clicking on the adhesive name.

Adhesive Viscosity [mPas] Base Curing* Properties
Vitralit® 1600 LV 3,000-5,000 epoxy UV
secondary heat cure
Very high Tg
low water absorption
low ion content
very high chemical resistance
Vitralit® UD 8050 8,000-11,000 acrylate UV
secondary moisture cure
fast moisture post-curing in shadowed areas
easy to dispense with jet or dispenser e.a.
resistant to moisture
fixing and protecting electronic components
Vitralit® UD 8050 LV 200-400 (Rheometer, 25°C, 5s^-1) acrylate UV,
moisture postcuring
Moisture post-curing in shadowed areas;
tack-free surface
Vitralit® UV 2113 19,000-32,000 (Rheometer, 25°C, 10s^-1) acrylate UV
Acrylate hybrid
superior strength
low thermal expansion
impact resistant
low shrinkage
resistant to soldering stress
excellent flow properties
Vitralit® UV 2114 10,000-15,000 (Brookfield LVT, 25 °C, Sp. 4/30 rpm) acrylate UV
Very good adhesion to many substrates;
for bonding and sealing of plastics, glass and metal
Vitralit® 6104 3,000-8,000 acrylate UV
secondary heat cure
Very high adhesion to metals and sintered materials
Vitralit® 6104 VT 80,000-90,000 (LVT, 25°C, Sp. 4/6 rpm); 8,000-17,000 (Rheometer, 25°C, 10s^-1) acrylate UV
secondary heat cure
Very high adhesion to metals and sintered materials
ideal for bonding large components on circuit boards (corner bonding)
Structalit® 3060 N 4,000-8,000 (Rheometer, 25 °C, 10^s-1) epoxy thermal non-conductive
high flexibility
very fast curing
very low ion content

*UV = 320 - 390 nm