Henkel launches thermal management materials for EV battery systems

According to Henkel, the new materials are designed to improve thermal transfer between battery cells and cooling systems while also supporting structural integrity and manufacturing efficiency. The products target challenges associated with rising battery energy densities and increasingly compact battery pack designs.

“Thermal management in EV batteries is still one of the biggest challenges for electrified mobility,” said Stephan Hoefer, global market strategy head for e-mobility at Henkel. “New designs targeting higher energy densities in battery packs bring along the requirement for multifunctional thermally conductive adhesives instead of classical thermal gap fillers.”

Henkel said its thermal interface materials portfolio includes both thermal gap fillers and thermally conductive adhesives designed for automated dispensing processes in battery manufacturing. The company has been expanding its range of polyurethane-based thermal management materials for EV battery systems in recent years, including injectable thermally conductive polyurethane adhesives and silicone-free liquid gap fillers.

With 1.7 W/mˑK thermal conductivity, Bergquist TGF 2030APS – a two-component filling material – enables efficient heat dissipation from the battery cell stack into the cooling plate in EV battery modules. Dispensable at a high rate (over 40cc/sec), it can be used in sensitive battery applications thanks to its silicone-free formulation and low compression force, minimizing damage risk during assembly.

In addition, Bergquist TGF 2030APS is designed for a reduced carbon footprint, reflecting Henkel’s strategic focus on developing low‑emission, more sustainable product solutions. Its room‑temperature curing capability further supports energy‑efficient processing during assembly, helping manufacturers advance sustainability objectives without compromising performance or productivity.

Loctite TLB 9270APS is a two-component polyurethane-based adhesive for electric vehicles with cell-to-pack battery designs. It delivers 2 W/mˑK thermal conductivity, along with high bond strength and electrical insulation properties, and is particularly well suited to aluminum and PET film substrates.

With rapid dispensing to support production throughput and energy efficiency, it offers a long working time (40-45 minutes in typical conditions). It is also solvent-free and formulated to comply with high regulatory and safety standards.

The company is positioning the materials as part of a broader push into EV battery assembly technologies, including lightweight battery architectures, debonding-on-demand systems for battery recycling, and AI-assisted adhesive design tools.

Thermal management has become a major focus for EV battery developers as higher-capacity cells generate greater heat loads during charging and operation. Poor thermal control can accelerate degradation and increase safety risks, particularly in high-energy-density battery packs.

Photo: © Henkel

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