Key Applications of Polyurethane Structural Adhesives in Power Battery Packaging Processes
As the new‑energy vehicle industry has advanced by leaps and bounds, the requirements for power‑battery safety, energy density, and cycle life have become increasingly stringent. Adhesives play a critical role, particularly two key categories: thermally conductive adhesives with excellent thermal management properties, and structural adhesives designed to prevent cell slippage within the battery pack. This paper focuses on the applications and performance advantages of polyurethane structural adhesives.
Shanghai Hinnel
Jul 20,2026
What are the main applications of polyurethane structural adhesives in power batteries?
Cell fixation and bonding: The cells of a power battery must be securely connected into modules, and polyurethane structural adhesive can tightly bond individual cells within the module frame, with an adhesion strength that meets or exceeds the industry standard of ≥. 15 MPa It must meet these requirements while also exhibiting excellent flexibility, capable of absorbing vibrations and impacts during vehicle operation to prevent cell delamination and cracking caused by movement. For example, BYD’s Blade Battery uses a hot-melt polyurethane adhesive to encapsulate the cells, significantly boosting production efficiency, and in puncture tests, the adhesive layer remains intact, effectively inhibiting thermal propagation.
Module-to-housing bonding: In CTP ( Cell to Pack Among mainstream battery technologies, polyurethane structural adhesive is used to bond battery modules to the battery pack housing, with a peel strength of ≥ 10N/cm , and in 120 It maintains stable performance at ℃, enhancing the overall structural rigidity while reducing the use of metal brackets and other structural components, thereby contributing to battery pack weight reduction.
Why choose polyurethane structural adhesive?
Polyurethane structural adhesives exhibit excellent bonding strength and weather resistance, ensuring stable adhesive performance even under harsh environmental conditions. Moreover, they offer superior impact and vibration resistance, effectively minimizing damage to battery packs caused by vibrations during operation.
Product Recommendations:
Hinnel HNPU7003 Series of polyurethane structural adhesives , strength > 10MPa , flexibility, and aging resistance, replacing bolts / Welding, reduce Pack Weight, cushioning against vibration and impact, and preventing short circuits caused by cell displacement.
- Low VOC , compliant with ROHS/REACH
- Excellent resistance to aging and chemicals.
- Adhesive dispensing can be performed by machine or by hand mixing.
- Strong adhesion to various substrates
- High thermal conductivity, high toughness, and high elasticity
Common issues during the application of polyurethane structural adhesives:
The bonded surface has poor adhesion and is prone to delamination.
This may be due to insufficient cleaning of the substrate surface, the presence of oil or grease, or excessively low ambient temperatures during application. Ensure thorough substrate preparation and carry out work at an appropriate temperature.
Bubbles and pinholes appear in the adhesive layer.
This is often caused by excessively high humidity in the construction environment, moisture on the substrate surface, or air entrainment during adhesive mixing. Before application, ensure the substrate is dry and mix the adhesive slowly to minimize air incorporation.
Severe glue flow and overflow.
Sealant flow typically occurs when the joint is too wide, the sealant layer is too thin, or the substrate is tilted during installation. To address this, control the joint dimensions, apply a sealant of adequate thickness, and adjust the substrate’s position.
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