Consumer adoption of electric vehicle (EV) 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 is required. Central to the production, cost-effectiveness and durability of EV chargers – from Level 1 residential to ultra-fast DC chargers – are materials that enable robust operational performance, component durability and protection from harsh conditions and handling.

For its part, Henkel 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, along with the in-field attributes of ruggedness, safety and reliability necessary.

Henkel solutions for DC fast charging stations.

Henkel solutions for AC charging stations.

Henkel solutions for charging connectors.

Materials in Henkel’s EV charging portfolio include:

• Thermal interface materials for secure safe and reliable operation
  
  Effectively dissipating heat – whether from 220 Volts or 1,000 Volts – delivers the safety and long-term performance necessary for EV charging devices. Henkel’s 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.

• 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.

• Tough 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. 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.

Consumer adoption of electric vehicle (EV) 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 is required. Central to the production, cost-effectiveness and durability of EV chargers – from Level 1 residential to ultra-fast DC chargers – are materials that enable robust operational performance, component durability and protection from harsh conditions and handling.

For its part, Henkel 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, along with the in-field attributes of ruggedness, safety and reliability necessary.

Henkel solutions for DC fast charging stations.

Henkel solutions for AC charging stations.

Henkel solutions for charging connectors.

Materials in Henkel’s EV charging portfolio include:

• Thermal interface materials for secure safe and reliable operation
  
  Effectively dissipating heat – whether from 220 Volts or 1,000 Volts – delivers the safety and long-term performance necessary for EV charging devices. Henkel’s 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.

• 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.

• Tough 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. 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.