Adhesives for Alternative Fuel Vehicles

Electric vehicles (EVs), hybrid electric vehicles (HEVs), and fuel cell vehicles (FCVs) offer substantial cost savings/energy efficiency over conventional internal combustion engine vehicles (ICEs). They also feature low to zero harmful CO2 emissions, quiet/smooth rides, low maintenance and rely on domestically produced more environmentally friendly energy resources. Complex subsystem interactions/controls, confined packaging requirements, harsh environments/operating conditions, safety, power management concerns need to be addressed to ensure peak performance.

Master Bond's comprehensive line of adhesives, sealing, potting/casting compounds, form-in-place gaskets, impregnation resins and thermal management materials provide sustainable solutions and protection against:

  • salt spray
  • mechanical shock and vibration
  • salt fog
  • thermal cycling
  • thermal aging
  • thermal shock

Innovative technologically advanced formulations have been developed to help meet new fuel economy standards, extend component longevity and save on warranty expenses.

HEV and EV Product and System Applications for Master Bond Adhesives, Sealants and Coatings

Environmentally friendly products offer lower processing costs in the assembly of:

  • Battery chargers
  • Power electronics
  • Wiring assemblies
  • Electric inverters/converters
  • Thermal systems
  • Motors
  • Battery packs
  • Battery management controllers
  • Sensors
  • Switches

Our expertise has enabled automotive OEM's tier one and tier two suppliers to rectify noise, vibration, harshness issues, ensure electromagnetic interference (EMI) free performance and provide mechanical support/durability/heat transfer for thermal interfaces in high density circuits. Compounds have been engineered to tightly seal battery cases, vacuum seal rotors, magnets, coils from porosity, pot/encapsulate inverters/converters, to resist high voltage and bond frames, laminated stator cores, bearings, heat sinks, connectors.

Specific products have been at the forefront for bonding aluminum alloys, high strength steel, magnesium alloys, fiber-reinforced composites to increase stiffness and lower weight. These systems have replaced traditional joining techniques such as welding/riveting and are designed to optimize ride handling, safety/crash performance. High expectations for volume production increases should make these vehicles more readily accessible and affordable. Special attention has been given to recyclability, reduced processing cycle times/manufacturing complexity, through precise automatic dispensing with stationary/mobile robots.

Enhancing Fuel Cell Durability and Corrosion Protection

Fuel cell technology has made major advances and has great potential. Hydrogen cell vehicles do not emit any greenhouse gases (only heat and water from the tailpipe), reduce noise levels, lower weight and refill rapidly. Master Bond has developed form in place and cured in place gasketing systems to prevent air leakage and moisture penetration for fuel cell stacking applications. Recent innovations include acid, coolant resistant structural adhesive systems and electrically conductive coatings. Automated application techniques for dispensing these compounds will improve processing efficiency for manufacturing fuel cell stacking. Overcoming obstacles in producing, storing, delivering hydrogen and designing/engineering more dependable, durable vehicles will result in large scale assembly and significant declining costs.

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