This case study demonstrates how Henkel and MauserCABS used structural adhesives to replace welding in the redesign of a lighter multipurpose vehicle cabin while also reducing CO2 emissions.

Application Challenges and Objectives

Data center switches, routers, and servers are incorporating larger, more powerful CPUs/GPUs to manage increasing data processing and bandwidth demands.

The new semiconductor packages, many containing multiple large dies, are seeing higher power concentrations, resulting in elevated operational temperatures.

At the same time, new generations of switch, router, and server designs are becoming more compact, which limits the thermal material types that are effective with very thin bond lines.

Customer Challenge

• Modern-day motor drives are integrating more complex power devices to manage growing energy efficiency requirements.  The customer’s next-generation motor controller required a thermal interface material (TIM) to manage new performance challenges and higher power densities. 
• As the IC power module is subjected to motor vibration, reliability and stability of the thermal interface material – with no material migration -- is critical to enable operational integrity.
• Any thermal material selected had to meet challenging metrics: Electrical isolation with high dielectric strength (>5000 Volts) and low thermal resistance are necessary to meet in-application conditions.

Henkel’s BERGQUIST® battery pack gap filler helps achieve reliable heat management performance in EV battery packs while vastly reducing the volume of worn out tooling parts entering the recycling and waste streams. When installed on the line, it reduced maintenance costs by 90%, lengthened service intervals, and reduced the number of worn parts headed for recycling or disposal. 

Henkel’s LOCTITE Thermal Propagation Prevention (TPP) solutions effectively contain thermal runaway to provide ample time for passengers to exit the vehicle in the event of a battery fire, while also contributing to improved sustainability through more efficient process application.

Emissions-free driving is essential to reducing carbon footprint. But to make the most impact, sustainability must be a strategic priority across the full vehicle lifecycle.