Material Adjustments that Adapt to EV Automation Requirements
The EV industry requires precision, efficiency and innovation. To keep pace with the speed of change and the growth of new technologies and solutions, automotive OEMs (Original Equipment Manufacturers) are seeking new ways to streamline assembly processes while remaining committed to serviceability and adaptability.
Automation is no longer just a buzzword. Rather, it is the key for EV OEMs as well as other industries to not only transform how things are done, but also to stay competitive in a rapidly changing marketplace.
Isaac Asimov, the famous American writer and professor of biochemistry, once said, “It is change, continuing change, inevitable change, that is the dominant factor in society today. No sensible decision can be made any longer without taking into account not only the world as it is, but the world as it will be.”
In the past five years alone, we’ve witnessed exponential growth. The concept of information technologies, powered by computation, is now a mainstream idea. We’ve seen unprecedented change in EV technology, artificial intelligence, space exploration, robotics, quantum computing, 3D printing and advanced material science, to name just a few notable areas. And don’t be surprised if we are only moments away from a self-flying car, which is also 100 per cent electric!
The bottom line: in an era where change is constant, unusually rapid and significant, materials, products and processes need to be adapted and customised to align with modern-day automation needs and future-focused strategies that can change the game by enhancing and speeding up today’s manufacturing processes.
In this Q&A with Patricia Adame, Sr. Applications Engineer, let’s explore how Saint-Gobain® Tape Solutions is keeping its finger on the pulse by working with customers to customise materials and processes for better alignment with automation needs.
Automotive OEMs require both precision and efficiency in their assembly process. How are the Saint-Gobain EV teams working with OEMs to tweak or adapt existing products and formulations for use in automation?
At Saint-Gobain Tape Solutions, we pride ourselves on customer centricity — our focus is to serve as a partner and not merely a material supplier. Our teams have gone the extra mile to connect with automation companies and learn how our materials can be adapted into automotive assembly processes. Recently, we’ve had a brilliant collaboration with KUKA, a German manufacturer of industrial robotics. Together, we were able to develop an automated process to install our Thermal Interface Material (TIM) pads, a product that typically requires significant manual handling.
What we’ve learnt from the partnership is that we could modify our TIM products to be successfully handled by automated systems, with some assembly aids, without compromising performance.
Watch how the thermal interface product ThermaCool® TC2006 Gap Filler is applied during an EV automation process.
How does working with automation companies and experts in the field influence the customisation of products and services to ensure serviceability and reworkability of products?
In working with many of our EV customers, we’ve learned that offering a broad solution involving assembly know-how helps ease the pain points for the design and release engineer while supporting the manufacturing side of the equation. Providing a complete solution, where automation is an option, and helping our customers understand how this can be implemented with our materials opens more opportunities.
We are not automation experts, but we are material experts. Thus, working together with automation suppliers allows each team to provide its expertise and collaboratively solve a challenging manufacturing issue.
By opening the door to these types of conversations and learning opportunities, we can determine where our products can be customised to provide the necessary support for automation, without impacting performance — whether that means mechanical, thermal, or electrical.
How does the Tape Solutions team use past knowledge or prior test results to drive new material innovations and advancements for integration with automated processes?
The first question we always ask a customer or potential customer is: “What is the intended use and application of the material?” The answer to this question helps guide us in providing an integrated solution for our customers. We might start by proposing a material that will fit the performance requirements, but if the material is not easy to handle, customers might seek alternative solutions. Our goal, as well as the goal of our customers, is to help optimise overall efforts, especially with regards to cost, weight, performance, and material handling.
Our teams work to gather as much data as possible to provide our customers with a wider picture of how the material could perform under different environmental conditions. This upfront knowledge helps us evaluate, with automation integrators, if any add-ons need to be considered.
Because many of these materials will be exposed to shipping and transportation conditions which could impact material form, fit, and function, we also perform environmental exposure ageing tests and review them with automation integrators to ensure no other factors need to be accounted for in providing the optimal solution for an application.
How are the Tape Solutions teams working together with R&D and customers to stay ahead of market demands such as being able to provide products that are easily disassembled, removed, and integrated into automation?
As electric vehicle technology evolves, so does the need for improved serviceability of battery packs. For instance, in the event of a damaged cell or electrical failure, OEMs often opt to replace a module rather than the entire battery pack. The ability to disassemble, remove, and replace components quickly and efficiently is crucial. Traditionally, TIM materials are applied in liquid form during assembly and cure over time. However, once fully cured, these materials can be extremely difficult to remove during repairs, often requiring scrapers or other tools that risk damaging surrounding components.
Our teams understand the importance of serviceability and, as a result, our TIM pads, for example, are specifically designed for easy removal and replacement. This helps to prevent damage to adjacent components.
Customers frequently approach us seeking de-bondable solutions. Our R&D team is actively developing other de-bondable adhesive solutions that can further simplify disassembly and enable quick repairs or rework during both the assembly process and the battery pack’s lifetime.
By offering materials that are easily removable and reworkable, we not only support OEMs’ needs for efficient repairs but also help to reduce service costs and downtime. This demonstrates our commitment to providing material solutions that simplify the repair and service process while maintaining high performance.
Why might a customer look to Tape Solutions’ products as being advantageous due to their ability to be disassembled quickly?
Being able to respond quickly while still delivering a product that meets customer requirements is the primary objective for OEMs. Manufacturing teams are always seeking solutions that offer assembly benefits, such as automated assembly or ease of replacement.
Cycle time is a key performance indicator for OEMs, so providing solutions that can be easily replaced helps our customers achieve their overall goals. It addresses their challenges not only by delivering effective material performance but also by offering an integrated solution.
Our products can be designed to enable easy disassembly and quick replacement without compromising the integrity of other components. By providing materials that are simple to replace or repair, we help OEMs reduce cycle times, enhance manufacturing efficiencies, and support their sustainability and performance objectives.
As we continue to evolve, innovate, and revolutionise the future of transportation, we must remain agile in our approach to new product development and adapt swiftly to new technologies, while maintaining high-quality standards. Tape Solutions is committed to remaining at the forefront of providing materials that meet the needs of both OEMs and automation experts.
In a world that is evolving faster than ever, the saying “the only constant in life is change” has become a truth that resonates deeply within the automotive and EV sector as well as many other sectors.
The future will undoubtedly be powered by advanced automation and electric systems that will redefine and shape a more efficient, sustainable, and thrilling future for transportation. By offering customised solutions that are easily integrated into automated systems, Saint-Gobain Tape Solutions is driven to support the future of automotive manufacturing and contribute to the continued evolution of electric vehicles.
It is through collaboration with companies like KUKA that we help drive innovations — together. Connect with our team today to share and start realising future-focused ideas today!