Whether due to government incentives to do so, the feel-good factor of going green, or the desire to keep up with the latest trends, more and more people are now turning to electric vehicles (EVs) for their next car purchase. This, in turn, has led to opportunities for manufacturers of EV charging points. Indeed, the worldwide market for these is predicted to grow to $111.9 billion by 2028. Compared to its 17.6 billion value in 2021.
Yet despite these strong forecasts, the EV charging industry currently faces niggling reliability issues. Recent investigations have shown that in some areas of the UK, up to 10% of charging points aren’t working on a given day, with this figure at around 20% in the US. In order for the electric vehicle industry to reach its full potential, these reliability issues need solving, and quickly.
Reliability, and the subsequent role of adhesives in EV charging point manufacture
Part of this reliability problem is caused by inadequate software like payment systems not working or charging point apps crashing. Another part of the issue comes down to less than optimal build quality of the charging unit, which seems to be an issue for manufacturers both big and small. Enter stage right: EV charging point adhesives!
The right adhesive serves to ensure a stronger, more reliable charging unit that can better withstand both internal and external stressors, such as harsh weather conditions. Secondly, as a result of this, they help to keep repair and servicing costs down. The right adhesive also ensures that servicing, when required, can be carried out easily, all the while offering top-notch protection to the charging unit when it isn’t. They typically also offer heat and other types of resistance due to how hot these charging units can become.
Permabond offers adhesives that serve a variety of different applications within this industry.
EV charging point adhesive applications
Potting adhesives for EV charger connectors:
The role of potting adhesives in EV charger connector cables is critical. They ensure a stronger, more durable charging cable by encapsulating the components within the connector housing. They also keep the electrical wiring within the charger firmly in place. These connectors are put in and pulled out of car chargers multiple times a day. Therefore, any adhesive used must be tough and able to withstand heat, impact, and also fire. Permabond’s MT382 modified 2-part epoxy is ideal for potting these applications. It offers excellent adhesion to nylon, ABS, polycarbonate, and other plastics, as well as various metals. It’s black and curable at different mix ratios depending on the level of flexibility required in the final product. A fully fire-retardant version is available on request.
Threadlocking:
Permabond offers a variety of threadlockers to suit almost any application. Our HH131 anaerobic threadlocker has high heat resistance (up to 230°C). A1042 has a rapid cure and high impact resistance, as well as being heat resistant up to 150°C. This adhesive, in particular, is great for assembling metal parts that may need to be disassembled and/or repaired later on, as is our MM115 medium-strength threadlocker.
Gasketing:
LH197 is a flexible metal gasketing adhesive, ideal for bonding dissimilar metals where differential thermal expansion and contraction might be an issue. MH196 offers less flexibility but excellent heat resistance, up to 200°C. Permabond’s TA4611 toughened acrylic adhesive is great for bonding plastic EV charger housing units.
Conformal Coatings:
Permabond UV681 UV-light curing adhesive is ideally suited for conformal coating applications such as those found in both AC and DC charging stations. It has a low viscosity, which ensures a smooth, bubble-free coating, as well as high-temperature resistance.
This article first appeared on Permabond’s website.
