A Robust EV Team: Driving R&D and Application Engineering to Leave a Global Footprint

Could you please tell us about yourself?

Dominique: I was born and raised in Mexico in a multicultural environment before moving to Europe to study Mechanical Engineering in France. Throughout my professional career, I have worked for various Saint-Gobain business units, most recently at Tape Solutions, where I have had the opportunity to follow the evolution of the EV market over the past 12 years.

Russell: I started working at the Granville, NY site 34 years ago when it was Norton Performance Plastics. At that time, my father, Lance, and grandfather, Roy, also worked there, so three generations of our family were present. I became part of the Saint-Gobain family and have been working in R&D for 33 years now.

Senthil: I am the Global Applications Engineering Manager for EV. I have been with Tape Solutions since 2008, holding various roles within R&D and Marketing departments. My expertise is in polymers, and I have over 25 years of experience in this area across different functional roles.

Could you share some insights about your current role?

Dominique: As the Global EV Marketing Manager, I interact with people around the world, including colleagues and customers. This global interaction allows me to stay in tune with the rapidly changing dynamics of the EV market.

Russell: I am currently the Senior Research Project Leader at the Granville site, where I work closely with our Senior Research Technician, Dave Elliott. Since we are the only two R&D employees here, we like to think of R&D as standing for "Russ & Dave." Our activities at Granville are varied and extend beyond EV applications to include developing new or modified products for a wide range of markets, such as automotive (EV, bonding & gasketing), transportation, semiconductors, construction, medical, and other industries. We also focus on raw material replacement, dual sourcing projects, and initiatives aimed at enhancing sustainability.

Senthil: My team focuses on understanding application needs, including unmet needs, evaluating product performance, and developing tools and test methods accordingly. It's an exciting space because we're at the forefront of creating new methodologies for assessing materials in response to the dynamic demands of the EV market. These techniques provide fresh insights into how products need to be modified or developed to meet the rapidly changing requirements of EV battery packs.

What, in your opinion, are the major advantages of EVs over traditional internal combustion engine (ICE) vehicles?

Dominique: I believe vehicle electrification is an essential step towards achieving a carbon-neutral economy and lifestyle.

Russell: While I don't yet own a fully electric vehicle, I enjoy my RAV4 Hybrid. Reducing our dependence on fossil fuels and saving on fuel costs while being more sustainable for our planet is certainly satisfying. The more we focus on these efforts, the better we become as a society. Being a pioneer is not easy, but it pays off in the long run. Shifting this paradigm requires a cultural change, which might seem slow, but as the saying goes, "slow and steady wins the race."

Senthil: EVs offer a much cleaner operation at the point of use. Particulate emissions are almost negligible with EVs, unlike ICE vehicles. It is crucial to consider the impact of vehicles on air pollution carefully and thoughtfully.

What new trends or innovations within the EV space are you most excited about?

Senthil: Current battery technology tends to become less safe as energy density increases, and vice versa. Therefore, innovations in developing safer, yet energy-dense batteries are very exciting. The commercialisation and widespread adoption of such technologies could be a game changer for the EV market.

Russell: It’s exciting to see OEMs embracing our holding and compression pads. Opportunities are growing, with more customers approaching the Tape Solutions EV team. In some cases, OEMs are even directing Tier suppliers on what products to use, and Saint-Gobain is a strong contender. We are eagerly pursuing new developments in EV foams with self-extinguishing properties to meet future needs.

Dominique: Immersion Cooling is poised to be the next big thing for improving the cell thermal performance and extending the battery lifetime. It will help to practically eliminate the risk of cell thermal runaway. Together with our partners, we are very closely following this trend to co-develop the appropriate cell compression materials for this cooling technology.

What are some nuances or differences you see regarding mainstream EV vehicle adoption globally?

Dominique: Like any new technology, EVs have an adoption curve, typically starting with "innovators" and "early adopters." As Geoffrey Moore vividly describes in his book, we now need to "cross the chasm" to reach the mainstream market. Depending on the region, mainstream segments are not yet ready to give up the perceived comfort of a petrol-driven vehicle for a CO₂ emission-free BEV (Battery Electric Vehicles), which still carries a higher price tag and requires careful planning for long-distance travel due to an underdeveloped public charging infrastructure.

How do you ensure that raw materials being used are compliant with safety standards and regulations?

Russell: Our Product Stewardship team is now well-integrated with R&D, creating a seamless relationship. The current standard practice is to gather all necessary regulatory information for Product Stewardship and local EHS Management approvals before bringing raw materials on site. This approach represents a significant change from previous practices and has had its challenges. However, it is now paying off. It was great to demonstrate this practice during a recent ISO audit.

Could you provide an example of a challenging customer co-development and your approach to it?

Russell: Achieving a UL V-0 flammability rating with polyurethane chemistry is extremely challenging, as it is much more combustible than silicone foam technology. However, this rating is a "gold" standard for EV applications. By using a range of specialised raw materials, we can disrupt the fire triangle enough to achieve this rating, even with relatively low-density foam. This is an exciting area of focus for us right now.

Could you share insights on efforts for becoming IATF certified at the Granville, NY manufacturing site?

Russell: ISO certification has been a hallmark of the Granville sites for many years, along with the sale of bonding tapes and gasketing foams into the automotive industry. The EV market has provided us with even greater motivation to meet the International Automotive Task Force (IATF) standard. Training courses are scheduled for multi-department personnel to achieve this goal. R&D is developing Design Failure Modes and Effect Analysis (D-FMEA) for EV foams and creating Process Maps. We are also implementing a new experimental parts number procedure for prototypes as part of design control.

What motivated you to pursue a career in EV application engineering?

Senthil: The challenges presented by the EV market are fascinating and drive us to innovate solutions more quickly than in more traditional, established markets. It’s always refreshing to learn new things and implement new solutions and products. This dynamic environment motivated me to build a career in this field.

From an application perspective, what questions do you ask upfront to mitigate challenges or drawbacks in future EV applications?

Senthil: Given that this is a constantly evolving field, our questions are always changing. This dynamic keeps things interesting as we continuously learn and implement new solutions quickly. We've learned that our questions should be aimed at identifying the customer's actual needs rather than just promoting our products. This approach helps us discover unmet needs, allowing us to propose solutions that reinvent products from their basics, leading to an optimal solution for the customer.

Why is dual functionality of material solutions important in addressing modern-day EV application challenges?

Senthil: There is a constant need to maximise the energy density of battery packs while ensuring the highest safety standards in their operation. Having a product dedicated to each function makes it challenging for our customers to meet market demands, regulatory requirements, and consumer safety expectations. Therefore, it’s not just about dual functionality; there is a need to integrate multiple functions into a single solution to succeed.

Dominique: EV battery pack protection is a multi-physics problem (thermal, mechanical, electrical). Thus, offering multifunctional solutions is the perfect fit to address the complex challenges of this young and dynamic space.

Through their diverse experiences and deep expertise, Dominique, Russell, and Senthil offer a glimpse into the global strategies driving success in the EV market. Their work reflects a holistic approach that blends regional market dynamics with a unified global strategy, helping position Tape Solutions as a leader in innovation and sustainability. 

By focusing on the intersection of customer needs, regulatory requirements, and technological advancements, they ensure that Saint-Gobain not only meets but exceeds the expectations of the global EV community. Their passion for innovation, dedication to sustainability, and commitment to quality exemplify the core values that drive Saint-Gobain Tape Solutions forward. As the EV market continues to grow and evolve, the cross-collaboration of our teams will undoubtedly shape a more sustainable and electrified future.