Inside Henkel’s Battery Application Center, where adhesive formulations meet production-line robots

Henkel has established an innovative Battery Application Center in Madison Heights, Michigan, designed to bridge the gap between laboratory research and full-scale production for electric vehicle (EV) battery adhesives. Unlike traditional companies that merely provide samples, this facility integrates production-intent dispensing equipment, including a six-axis ABB robot and pump systems tailored for large EV battery housings. This setup allows original equipment manufacturers (OEMs) and battery producers to test their actual components under real-world dispensing conditions, generating valuable data on bead application, flow rates, temperatures, and material behaviour at production speeds. The centre’s advanced dispensing system supports a wide range of materials such as polyurethanes, epoxies, thermals, and silicones, accommodating both one- and two-component cartridges and bulk dispensing formats. Senior application engineer Chloe Jindra highlighted the flexibility of the robot cell, which can switch between multiple dispense heads without requiring a rebuild, ensuring precise control over factors like flow rates and bead size. The heated pump systems maintain optimal viscosity levels, crucial for consistent application at the elevated temperatures typical of production lines, while safety protocols enable seamless operation whether customers are present or not. A significant focus at the Battery Application Center is developing adhesives that can be de-bonded on demand, addressing the challenges of in-plant rework, field repairs, and end-of-life recycling. Senior manager Matt Boback explained the dual triggers—electrical and thermal—that enable safe and controlled disassembly of battery packs. This approach aims to balance the need for durable adhesive bonds during normal operation with the ability to cleanly release components when necessary, a complex engineering task given the tightening repairability and recycling regulations in Europe and North America. Ensuring that adhesive solutions perform consistently from lab-scale trials to high-volume production is another critical challenge addressed at the centre. Boback emphasised the importance of matching dispensing parameters such as temperature, speed, bead geometry, and pressure across different scales to guarantee reliable application on customer production lines. Vice President Pankaj Arora noted that the facility not only supports customer projects but also feeds insights back into Henkel’s product development, enabling the company to refine materials based on real-world requirements and emerging battery technologies. The use of digital twin modelling further accelerates development by reducing the need for physical prototyping.