Nicolas Morel, Business Development Manager E-Mobility at Sika, discusses with the editorial team of the magazine "Automotive Industry" some of the challenges of E-Mobility today.
Automotive Industry (AI): What are some of the challenges facing automotive OEMs today when manufacturing electric and hybrid vehicles?
Nicolas Morel (NMo): Besides affordability which remains the number one challenge of the transition to electric powertrains, to take the lead in this developing segment, OEMs have to deliver to their customers reliable, durable and safe vehicles. Other topics include resolution of the charging network, charging cycle time, driving range and vehicle top speed drive are key parameters for end user adoption between the numerous brands present in the market. Challenges do not only effect the OEM, but also tier suppliers along the supply chain. Combinations of platforms – hybrid or native BEV - also present a mix of design options on component assembly, body structure, materials mix and the incorporation of NEV or full electric drivetrain components. Adhesives and sealants play an expanded role in all cases, therefore providers should have a wide technology range, like Sika.
AI: How do your company’s products help meet these challenges?
NMo: Sika is a key supplier for body structure and component assembly technologies, and is well established in that regard. Our solutions also run deep into the new powertrain systems. Key factors that directly drive performance and safety of New Energy Vehicles are heat control and dissipation; heat is the enemy of high performing battery systems. Our latest innovations for Thermal Management in Battery Systems includes Silicone-free Thermal Conductive Adhesives and Gap Fillers, providing the best performance for optimum heat transfer in Battery Packs and Modules. Moreover, we have recently developed 2-component epoxy resins for e-Motor Stator encapsulation that enhances motor performance while facilitating design options, weight reduction and throughput improvements in manufacturing by cutting cycle times. Our solutions also include multiple dielectric potting chemistries for controllers and on board chargers, as well as harnesses and connectors. Bonding and sealing enclosures is a Sika core competency, and we are there as well.
AI: In new vehicles, light-weighting for greener vehicles, as well as comfort and safety are of paramount importance – how can Sika help in all three areas?
NMo: Lightweight, Comfort and Safety are not new trends in our Automotive business. Identified as megatrends more than a decade ago, Sika is vested in development and application of innovative solutions in those three segments. It is now and continues to be a part of our DNA. These products are proven to tackle those challenges with our novel joining solutions for Multi-Material Assembly, Light weight reinforcement systems for crash performance improvements as well as our industry leading full range of acoustic parts and sound damping solutions that perfectly complement electric power train requirements. NEV powertrains offer further opportunity for deployment of hi-performance Sika technology with a product range that has been selected and readied in advance of the current state.
AI: What are some of Sika’s latest technologies for new vehicles and how do they compare to traditional adhesives?
NMo: To put it simply, one of the biggest challenges that comes along Electric Vehicle design and manufacturing is the multiplication and type of materials used in the construction of electric power trains. The challenges are answered with our wide range of products and knowledge because we have prepared for the future. We also have a broad pallet to select from based on our global portfolio– 1C, 2C and boosted PUR, Silicone, STP, MMA, Epoxy, hybrids, dispersion coatings, hotmelts and PSA. There are many different approaches between our customers that are answered by our full product range approach. We continue to be creative in developing new bonding solutions that overcome challenges in diverse applications; adhesion on bare metals, plastics and composites, while offering answers to heat and glycol resistance, as well as to accommodate the constant delta-alpha effects when joining multi-materials - all in cold assembly process conditions.
AI: What are the challenges in battery box construction with EVs’ battery cells? How has Sika managed to find effective solutions?
NMo: There are two primary areas where selected materials need to outperform in the Battery cell operating environment: Heat transfer and fire resistance. Sika offers a wide range of thermal conductive and fire resistant silicone-free bonding systems that allows optimal assembly and long term performance of battery cells. Further, we combine our intumescent coatings to avoid heat runaway in battery modules, and to protect in an ultimate failure situation by suppressing the spread of smoke and fire outside of the battery box. Our product range specific to battery components has been tailored to where we can best add value with performance.
AI: Give us an idea of the importance of R&D to Sika and how the company works with customers to find solutions for the vehicles of tomorrow?
NMo: Courage for Innovation is one of our company’s seven core values. It is embedded in the culture of our company and in the way we approach our customers. We walk the talk. R&D is a vital investment. We seek interaction and customer partnerships that lend themselves to further technological reach. We are also an anticipatory organization, meaning products available today were blueprinted several years ago based on shared vision. Our R&D efforts continue to yield tomorrow’s products realizing tomorrow is often 5 years away. The entire organization remains engaged in partnership relationships with customers and with industry consortiums which contributes to a clearer view of tomorrow’s vehicle needs no matter what form they take.
AI: What is Sika Automotive’s strategy over the next five years in terms of the fast-changing automotive landscape?
NMo: We continue to be customer focused and active in the market segments we serve, while we continue to monitor, analyze and answer global megatrends in the broad sense of the segments we serve. We are, and always will be a solution provider. We are currently addressing the next generation of challenges prior to arrival. While the Automotive landscape may experience change our constant focus is that our solutions remain value added, and fast change from our view presents additional opportunity.