Consumer adoption of electric vehicles (EVs) has grown significantly over the last year alone, representing 26% of new vehicle sales globally, according to industry analyst IDTechEx. As environmental consciousness and sustainability continue to influence buying behavior, EV unit sales are projected to continue on this trajectory and expand as much as 30% through 2030, by some estimates.
To ensure this positive, CO2-reducing trend maintains its steady acceleration, a significantly expanded EV-charging infrastructure. Central to the production, cost-effectiveness, and durability of EV chargers (from Level 1 residential to ultra-fast DC chargers) are the materials that enable reliable operational and protection from harsh conditions and handling.
For its part, Henkel — a manufacturer of adhesives, sealants, and functional coatings — has designed a select, proven collection of sealing, potting, and thermal-management solutions that provide the automation-friendly features required for mass production and deployment that ensure safety and reliability.
Materials in Henkel’s EV charging portfolio include:
- Gasketing and sealing to defend against damaging contaminants – Exposure to changing environmental conditions, moisture, and dust can damage sensitive components and reduce their operational life. Henkel sealants and Sonderhoff formed-in-place-foam-gasketing (FIPFG) technology offer customized, mass production solutions to shield internal systems from harmful contaminants.
- Strong protection with high-performance potting formulations – As the interface of charging power to the EV battery system, the reliability of charging connectors is critical. Constant plugging and unplugging, rough handling, and the potential for vehicle rollover require connector protection solutions that can withstand harsh conditions. Cost-competitive, performance potting materials from Henkel enable complete encapsulation of cables and wires within charging connectors, providing long-lasting durability and defense against moisture ingress for high-voltage parts.
- Thermal-interface materials for secure safe and reliable operation – Effectively dissipating heat — whether from 220 or 1,000 volts — delivers the safety and long-term performance necessary for EV charging devices. Henkel’s trusted Bergquist brand phase change, GAP PAD and gap-filler thermal interface materials (TIMs) help maintain stable operation of EV chargers’ power modules and high-density components.
Together, Henkel’s customized, proven EV charging materials portfolio delivers for system manufacturers and EV owners, says Justin Kolbe, Director of Market Strategy for Power and Industrial Automation.
“With solutions that are easily automated, costs are driven out of the manufacturing process while building reliable, rugged devices that will satisfy consumer expectations for all levels of EV charging devices,” he says. “In combination with Henkel’s global footprint, skilled global technical support team, and a deep understanding of compliance requirements in all regions, our select materials for EV chargers play an integral role in supporting reliable, low-cost, sustainable production and deployment to maintain the EV growth momentum.”