Adhesives

These are multifunctional materials that act as:

• thermal interfaces
• structural bonding agents
• vibration dampeners

There are three primary chemical options:

1. Silicone Adhesives – low modulus and highly elastic, so they tolerate thermal expansion well; often preferred for pouch cells, which are sealed in a flexible aluminium-plastic laminate rather than a rigid metal case [1]
2. Epoxy-based Adhesives – high modulus and strength with strong adhesion to metals and composites, widely used for structural, load-bearing bonds in cell-to-pack and cell-to-chassis architectures; the trade-off is brittleness at low temperature and limited reworkability once cured [1]
3. Polyurethane (Urethane) – good at absorbing vibration and accommodating mismatched thermal expansion between dissimilar materials, and lower density than epoxy, which helps with pack-level weight targets [1]