Material Adjustments that Adapt to EV Automation Needs
The EV industry requires precision, efficiency and innovation. To keep up 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 staying 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 stay competitive in a quickly changing marketplace.
Isaac Asimov, 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 last five years alone, we’ve witnessed exponential growth. The idea of information technologies, powered by computation is now a mainstream concept. We’ve seen unprecedented change in EV technology, artificial intelligence, space exploration, robotics, quantum computing, 3D printing and advanced material science, just to name a few notable areas. And, don’t be surprised if we are just moments away from a self-flying car, which is also 100 percent electric!
The bottom line: in an era where change is constant, unusually rapid, and significant, materials, products, and processes need to be adapted and customized 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 dive into how Saint-Gobain® Tape Solutions is keeping its finger on the pulse by working with customers to customize 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 only 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 great 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 learned from the partnership is that we could modify our TIM products to be successfully handled by automated systems, with some assembly aids, without compromise to performance.
Watch how 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 impact the customization of products and services to ensure serviceability and re-workability 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 customized 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 optimize 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 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 aging 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 serviceability need of the battery packs. For example, in the case of a damaged cell or electrical failure, OEMs often choose to replace a module instead of the whole battery pack. The ability to disassemble, remove, and replace components quickly and efficiently is critical. Traditionally, TIM materials are liquid dispensed during assembly and cure over time. However, once fully cured, these materials can be very difficult to remove during repairs, requiring scrappers or other tools that could damage surrounding components.
Our teams recognize the importance of serviceability and, because of this, our TIM pads, for example, are specially designed for easy removal and replacement. This prevents damage to adjacent components.
Customers often come to us looking for de-bondable solutions. Our R&D team is actively working on other de-bondable adhesive solutions that can make disassembly even easier and enable quick repairs or rework during both the assembly process and throughout the battery pack lifetime.
By providing materials that are easily removable and reworkable, we not only help support OEMs needs for efficient repairs, but also help reduce service costs and downtime. This is an example of our commitment to offering material solutions that can ease 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 react fast while still providing a product that satisfies the customer is the main goal for OEMs. Manufacturing teams are always looking for solutions that provide assembly advantages, such as automation assembly or ease of replacement.
Cycle time is an important KPI for OEMs so providing solutions that can be easily replaced helps our customers reach their overall goals. It alleviates their pain points, not only by providing successful material performance but also by providing an integrated solution.
Our products can be designed to offer easy disassembly and quick replacement, without compromising the integrity of other components. By providing materials that can be easily replaced or repaired, we can help OEMs reduce cycle times, improve manufacturing efficiencies and support sustainability and performance goals.
As we continue to evolve, innovate, and revolutionize 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 customized 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 realizing future-focused ideas today!