Case Study: Super-Fast Charging in Electric SUVs with DuPont™ BETAFORCE 2800 TC

In this case study, we explore how DuPont's BETAFORCE 2800 TC was successfully used to enable super-fast charging in Audi electric SUVs.

Table of Contents

audi e-tron super-fast charging
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The Project: Enabling Super-Fast Charging with DuPont™ BETAFORCE 2800 TC

During the development of one of the first all-electric SUV model, engineers were looking for an adhesive material that enabled super-fast charging technology. Through the help of DuPont, the formulated solution manages to enable super-fast charging while optimising thermal management, driving range, vehicle performance and module lifecycle.

The Problem

The most common problems that exist within the electric vehicle industry include:

  • Thermal management of battery packs – optimally, batteries operate at 25°C and below 60°C while charging.
  • Limited driving range
  • Limited battery life
  • Long battery charging time

They sought to reduce the extent of these factors within its new electric SUV to improve the experience of its customers. This meant that they required a solution that reduced the time it takes for battery charging (super-fast charging), preventing the generation of excessive heat and enhanced battery life and performance.

The Solution

DuPont representatives worked with the manufacturer to formulate BETAFORCE 2800 TC as an adhesive solution to their problems. BETAFORCE 2800 TC is a thermally conductive adhesive that is perfect for bonding composites and other dissimilar materials in lightweight designs, including modular assemblies. It can also be used to bond coated metal surfaces, such as steel, carbon fibre and SMC to aluminium. It has been specifically designed for battery assembly and can be dispensed from bulk containers into standard meter mix application equipment.

BETAFORCE 2800 TC allows for fast dispensing required in vehicle assembly processes due to its enhanced shear thinning behaviour. It was also shown to meet heat-cure performance, mixer dwell times, pump pressures, and press-in forces during vehicle testing.

The Benefits

betaforce 2800 tc super fast charging

Through using BETAFORCE 2800 TC, the 95kWh battery is able to operate at optimum temperatures during driving and charging, delivering more than 400 km of driving range as a result. Additionally, BETAFORCE 2800 TC has facilitated the use of 150kW super-fast charging, allowing drivers to quickly recharge without any worries of wasting time.

Furthermore, this solution dampens vibrations in the vehicle, enabling a quieter-running electric drivetrain, which further improves passenger experience and satisfaction. Another unexpected benefit is the improved handling of the vehicle, which was achieved by the placement of the bonded battery in the floor compartment of the vehicle, leading to a low centre of gravity.

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