Functional Coatings for

Battery Electric Vehicles

John Kukalis
March 12, 2019

Driving the Charge.

Agenda

1. Who is Henkel?
2. Market Drivers in Automotive and eMobility
3. Functional Coatings and BEVs
4. Conductive Coating in Lithium Ion Battery
5. Corrosion Protection in Key Battery Applications
6. Functional Coatings for Battery Packs
7. Questions

Functional Coatings for Battery Electric Vehicles March 12, 2019 2

Who is Henkel?

Adhesive Technologies Beauty Care Laundry & Home Care

Functional Coatings for Battery Electric Vehicles March 12, 2019 3

Market Dynamics
Drivers for Change in the Automotive Market
Environment & Regulation
▪ Environmental awareness
▪ Environmental pressure and
government regulation on
CO2 emissions, etc.
▪ Target setting for recycling
rates
Demographics Emerging Markets
▪ Aging population ▪ China as the largest
▪ Urban growth automobile market
▪ Rising middle class ▪ Increase in net disposable
(next billion consumers) income
▪ Change in mobility patterns ▪ Investment shifting from
West to East
Functional Coatings for Battery Electric Vehicles March 12, 2019 4
Changes Influenced by E-Mobility
Forecast for Mixed Material Usage on EV Body Structures
2010 2040

4% 1% 5% 2%
5% 15% 5%
10%
5%
15%

10%
55%

25%
15%
12%
16%
Mild Steel High Strength Low Alloy Mild Steel High Strength Low Alloy
High Strength Steel Advanced High Strength Steel High Strength Steel Advanced High Strength Steel
Ultra High Strength Steel Boron/Martensite Ultra High Strength Steel Boron/Martensite
AL 5000/6000 Aluminum/High Strength AL 5000/6000 Aluminum/High Strength
MG CFRP/Comp. MG CFRP/Comp.

Source: Center for Automotive research , 2017

Functional Coatings for Battery Electric Vehicles March 12, 2019 5
Value of Functional Coatings for BEVs

1. Protects critical components from corrosion and external elements

2. Increases battery life
3. Promotes increased adhesion for long-term durability
4. Enables lightweight materials throughout

Functional Coatings for Battery Electric Vehicles March 12, 2019 6

Functional Coating Applications for BEVs

Battery Cell Power Conversion Electric Drive System Battery Packs

▪ Conductive ▪ Inverters ▪ E-Motors ▪ Battery Trays

coatings ▪ Cooling Plates

Innovative technologies with focus on sustainability, lightweight & efficiency

Functional Coatings for Battery Electric Vehicles March 12, 2019 7
Conductive Coatings in Lithium Ion Battery

Battery Cell Power Conversion Electric Drive System Battery Packs

▪ Conductive ▪ Inverters ▪ E-Motors ▪ Battery Trays

coatings ▪ Cooling Plates

Functional Coatings for Battery Electric Vehicles March 12, 2019 8

Conductive Coatings in Lithium Ion Battery

The conductive coating

▪ Protects the current collector

MnO2 + Li+ + e- => LiMnO2

Conductive
additives Active Conductive Coating
from corrosion Anode Cathode
(Carbon) material

▪ Promote adhesion between

Li => Li+ + e-
Electrolyte

current collector and active

materials
▪ Increases conductivity
between actives and the Passivation film Aluminum Current
Cu Current AI Current
current collector Collector Graphene Li+ Solvent
Molecule
Collector (AIF3, AI2O3) Collector

Conductive coatings protect the current collector & enable the cell to
retain capacity
Functional Coatings for Battery Electric Vehicles March 12, 2019 9
Increase Lithium-Ion Battery Performance

Technology Introduction Features & Benefits Typical Application

▪ Reduced electrical
Tests on coin resistance between active Cathode of Battery Cell
cells NMC 111
material and Aluminum Henkel Coating Active
material
foil
Best
performance
▪ Low cell resistance also
maintained over many
charging cycles
Al
▪ Henkel Bonderite EB012: foil
80% initial capacity
358 cycles to 80 % of initial
capacity (273 % rise versus
Al untreated)

High performance & cost-efficient coating outperforms standard carbon-

coated Al-foils
Functional Coatings for Battery Electric Vehicles March 12, 2019 10
Corrosion Protection for Inverters, Electric Drives and
Battery Trays
Battery Cell Power Conversion Electric Drive System Battery Packs

▪ Conductive ▪ Inverters ▪ E-Motors ▪ Battery Trays

coatings
▪ Cooling Plates

Functional Coatings for Battery Electric Vehicles March 12, 2019 11

BONDERITE Electro Ceramic Coating
About
Multi-functional coating
deposited through plasma
deposition based on titanium
oxide.
Functionality
Deposits create a closed pore structure of 3 –
12 microns on most alloys
Coating forms readily on aluminum, titanium
and aluminized and aluminum plated
substrates
Process can be adapted for Magnesium
applications
Functional Coatings for Battery Electric Vehicles March 12, 2019 12
BONDERITE Electro Ceramic Coating
Benefits

Superior corrosion resistance with scribe >

3000+ hours on 2024 sealed

Under topcoat corrosion resistance with scribe

> 5,000 hours on 2024

Temperature resistance > 600C

Hardness of 400 – 900 Hv

Good flexibility; excellence paint adhesion

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Titanium Polymer Coating
BONDERITE M-NT 5200
About Benefits
Titanium-based conversion
Non-Chrome, thin-film coating process with
system for aluminum and
good design flexibility
magnesium

Metal Initial
Final
% change Excellent base for paint or adhesive bonding,
(APGE) different coating weights for different
Aural 2 35.55 32.4 9%
Alcan 65300 43.61 39.13 10% applications
A-356 49.34 46.82 5%
Hydro 6063 42.31 36.58 14% Bath control by titration and pH. Automatic
Aural 3 47.86 39.23 18%
Alcan 67425 44.96 44.09 2% feed capable
(Adhesive bonding data. Lap shears)

Functional Coatings for Battery Electric Vehicles March 12, 2019 14

Functional Coatings for Battery Packs

Battery Cell Power Conversion Electric Drive System Battery Packs

▪ Conductive ▪ Inverters ▪ E-Motors ▪ Battery Trays

coatings
▪ Cooling Plates

Functional Coatings for Battery Electric Vehicles March 12, 2019 15

Dielectric Coatings

About Benefits

Forms a dry layer or coating that Electrically insulates the cooling plate from
excludes moisture and reduces electrical shock to ensure integrity of the
friction, binding and wear. battery pack.

Withstands extreme conditions.

Functional Coatings for Battery Electric Vehicles March 12, 2019 16

 Thermally Conductive Dielectric Coatings

Standard Product
Details
Offerings
• Thermal conductivity – 0.7 to 1.0 W/m-K
Thermal Performance • Thermal impedance – greater or equal to 0.15C-
in2/W
• Thick dielectric coatings
• Various cure mechanisms
Other Attributes
• Silicone and non-silicone based solutions
Reinforced dielectric • 94 VO UL rating
DC/DC platforms
• Electro-statically attached
Method of Placement
• Printable solutions

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 Thank you!

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Driving the Charge.
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