Adhesion Matters - Adhesives for Automotive Electronics (Henkel)

Episode Date: August 3, 2025

Henkel offers comprehensive solutions for automotive electronic components, addressing key industry trends like autonomous driving, electrification, and heat generation. This episode features Henkel's product portfolio (LOCTITE®, TEROSON®, BERGQUIST® and TECHNOMELT®) across various applications such as ADAS components, control units, displays, infotainment, sensors, actuators, and wire harnesses. We detail specific thermal management, bonding, connecting, protecting, and sealing solutions, including thermal interface materials, adhesives, potting compounds, and coatings, emphasizing their role in ensuring the reliability and long-term performance of automotive electronics.

Welcome to the deep dive, where we take a stack of sources and extract those crucial nuggets of knowledge. Today, we're inviting you to look at your car not just as, you know, a machine, but as this silent revolution on wheels. Beyond the sleek paint or the powerful engine, there's an incredible electronic brain, hard at work, powered by some real unsung heroes. We're taking a deep dive into the highly specialized materials that make everything possible, from your car's advanced safety features to those, well, dazzling, dashboard displays. Yeah, and our mission for this deep dive is really to unpack the invites from a pretty comprehensive document, ankle solutions for automotive electronic compayments. We'll get into how cutting-edge material science is solving these critical challenges,

things like heat management, structural integrity, environmental protection, all the stuff that's making our cars smarter, safer, and yeah, truly more connected. You'll discover some surprising facts, I think, about what really goes into these crucial components. Okay, let's unpack this then. When we think about automotive electronics, it feels like it's exploded recently. It's way more than just bigger touchscreens, isn't it? What are the big trends driving innovation in this space right now? Absolutely. It's much bigger. If we connect this to the wider picture, we see several really critical market trends. And these are demanding incredibly sophisticated material solutions. Take heat generation, for instance. Modern cars are

just packed, absolutely packed with high power components, tiny semiconductors, and all these electronics crammed together, they generate a lot of heat in very small spaces. Right. Intense heat. Exactly. And this is driving a desperate need for better thermal solutions. You need materials that can actually move heat away efficiently. Keep things from, well, literally melting down.

So it's not just shrinking the components. It's battling that heat buildup when they are small and powerful. Yes. It's like a constant engineering headache. Oh, it is. A huge one. Then you've got increasingly strict environmental standards. We're talking global safety regulations, chemical compliance, like,

reach or RoHS and recycling guidelines too. These push manufacturers to find more sustainable solutions, lighter weight solutions for pretty much everything inside the car. And for you, the driver, passenger comfort, and aesthetics are massive now. Those seamless, really integrated designs in your cabin. They demand assembly materials that allow for these beautiful, clean looks without sacrificing an ounce of durability or safety. Ah, so that sleek, high-tech feel isn't just clever design.

It's actually enabled by the glues and materials holding it all together. What about how these cars are actually made on the factory floor? Good question. That brings us to manufacturing efficiency. Modern car production is incredibly high speed. It demands materials that cure really fast, are easy to process automatically, and deliver perfectly repeatable results. Every single time, no variations. Consistency is key.

Totally. And of course, connectivity is just paramount today. Your car is basically a mobile data hub now, which means all those highly integrated components need solutions that enable that seamless connection. But also actively protect against unintended interactions like electromagnetic interference or EMI. Right, you don't want your phone interfering with your car sensors. And crucially, road safety. ADS advanced dragor assistance systems, they're becoming pretty standard now, aren't they?

Exactly. Standard and increasingly complex. the precision and flawless functioning of ADS components, you know, your car's digital eyes and ears, cameras, radars, lightars, they demand assembly solutions that meet incredibly strict automotive reliability standards. Failure is just not an option. What's fascinating here is how companies like Henkel are tackling these diverse challenges.

It's not just individual materials, but with a whole broad technology portfolio. I think thermal management, bonding, connecting, protecting ceiling solutions, all of it. And it's backed by deep process expertise, too. Right, a whole toolbox. So we've got this big picture of why these materials are needed. But what does this actually mean for the components inside your car? Let's let me zoom in a bit. Starting with safety seems right. When we talk about 80s, the sheer precision needed for things like cameras and lighters, it's kind of mind-boggling. How do materials make sure they see the road perfectly every single time year after year? Yeah, it is critical. For 80s cameras and

LIDARs, you need absolute exact alignment and thermal stability. Imagine there's this revolutionary one-step adhesive locked-tight obelastic NCAA NCA 0-1 UV. It cures fully in just three seconds with UV LED light. Three seconds. Yeah, incredibly fast. And this isn't just good for manufacturing speed. It's critical because it locks components in the place with just phenomenal precision. It prevents any blur or drift in the camera's view over time or with temperature changes. It also has a high glass transition temperature, the TG, meaning it stays rigid and stable, even when temperatures inside the car swing wildly. A low coefficient of thermal expansion, CTE, so it expands and contracts minimally, all about

maintaining that perfect alignment. That's speed and microscopic stability. That sounds like a genuine game changer for assembly lines and reliability. Okay, what about radars then? They've got that dual challenge, right? Protecting from electromagnetic interference and managing heat at the same time. That's a great point. And a perfect example of where a single material can solve multiple problems.

Take a specialized gap pad, like the Birdquist Gap Pad TGP EMI 4,000. It's a soft, conformable material fills the tiny gaps between, say, the radar chip and its housing. This one doesn't just transfer heat efficiently. It's got a 4.0 WMK conductivity, which is good. But it also absorbs electromagnetic energy, up to 77 Gugerts in this case. It prevents interference with other vehicle systems. So it's like a silent bodyguard keeping the radar clear and cool. Exactly. EMI protection and thermal management in one pad.

And for sealing the radar modules themselves, protecting them from the elements, there are things like octite SI5972 FC. There's one component silicone-based formed-in-place gasket or FIPG. It cures quickly, allows for rapid assembly, and creates this really robust seal against moisture and dust. And then the actual control modules, the brains running these agass systems, they need incredibly robust solder-drant reliability, right? Especially with all the vibrations and temperature change as a car goes through.

Oh, absolutely critical. For control modules, just imagine the intense vibrations, the heat cycles, those critical circuit boards endure. There's an epoxy-based underfill material. Locktight, Echo Bond, UF 1173. Think of it as this super thin protective layer. It flows into the tiny gaps under and around solder joints on a circuit board and then hardens, making them incredibly strong and stable, reinforcing them. Like microscopic concrete. Kind of, yeah. A very specialized, thermally stable concrete. Its glass transition temp is exceptionally high, 159 degrees Celsius. So it locks those solder joints in place even in scorching engine compartment temperatures. This isn't just about reliability on day one. It's about ensuring your car's brain never clitches due to a loose connection, even years down the road under extreme stress.

And you mentioned it earlier being CMR-free, no carcinogens, mutagens, or reproductive toxins. That's a really significant benefit for worker safety during manufacturing. Okay, that makes sense. Let's move inside the cabin now, the displays. They're getting bigger, brighter, more integrated. What unique material challenges do they present beyond just, you know, looking good? Well, looking good is part of it. But it really centers on the user experience and long-term durability.

Optical clarity is paramount, obviously. Antifigurent properties are becoming huge and robust bonding to ensure longevity. Take liquid optically clear adhesives or, oh, geez. Locktite A-A-8671 PSA-A-D is an example. These are UV or visible, light-curable acrylics. They fill any tiny air gaps between the display layers that cover glass and the actual display panel. This improves optical performance, dramatically makes colors pop, increases contrast, reduces reflections, and also boosts durability. It makes the screen tougher.

So it's not just sticking glass to a screen. It's ensuring optical perfection for that crystal clear image we expect now. Precisely. And to keep those big screens looking pristine fingerprints. Yeah. Exactly. There's an ultra-thin, transparent coating, lock-tight, invisiprint.

It's fluorine-free, which is important environmentally. And it drastically reduces those annoying fingerprint smudges, which, let's be honest, is a real battle on those massive dashboard screens. It also minimizes outgassing, releasing volatile compounds, which prevents that annoying hazing or fogging you sometimes see develop on displays over time. Okay, anti-smudge tech I can get behind. What about holding the whole disdemeanor? display unit together.

Right. For the structural bonding, say, attaching the display module frame to the dashboard structure. There are adhesives like Octite MS-650. It's a black, fixotropic, silene-modified polymer adhesive. Thixotropic just means it flows easily when you apply pressure, like dispensing it, but then it holds its shape immediately. It doesn't sag. This gives it high green strength, holds things in place right away and forms a skin quickly,

speeding up assembly. And what about those head-up displays, the ones that project info onto the windshield? That seems tricky. tricky. For head-up displays or huds, you often need to bond to similar materials, maybe plastic components to the glass windshield itself. These materials expand and contract at different rates with temperature changes, which can stress the bond. So a special type of polyurethane-based reactive hot-melt adhesive, like a lachyte HD 3597, is ideal here. It remains soft and flexible even after curing, allowing for that slight differential movement without

breaking the bond, and it offers strong adhesion with a very short open time, meaning it grabs quickly and sets fast. Okay, so specialized glues for specialized jobs. Beyond the obvious displays in cameras, though, there are just countless hidden sensors and actuators making our cars work. Think engine management, climate control, parking sensors. How are they protected from all the nasty stuff under the hood or chassis, heat, vibrations, moisture?

Yeah, it's all about ensuring their long-term functionality in a really harsh environment. Protection is key. For instance, in ultrasonic sensors, like your parking sensors, there are two component potting resin systems. Firm sole 33 to 4 is one. Potting just means completely encapsulating the electronic components inside the sensor housing with a protective material. This particular one forms a flexible silicone foam. And that foam provides piso damping, basically.

It absorbs vibrations that could interfere with the sensor's operation, ensuring consistency and accuracy. Okay, like a little protective cushion inside. Exactly. You also have epoxy-based thermal potting resins like, P.E. 8086. These aren't just electrically insulating, but they're also resistant to very high temperatures up to 180 degrees C, and crucially resistant to things like automatic transmission fluid, ATF, so they can protect sensitive electronics located right near the transmission or engine. That's some serious, robust protection for really vital systems.

Definitely. And for more general encapsulation of sensitive electronic bits, there are highly flowable two-component polyurethane-based potting resins. Tereson, P.U., U-137s, U102 as an example. These flow easily into complex shapes, completely sealing the components. They insulate them electrically and protect them really well against physical shock and vibration. And thinking about connections. What about the massive networks of wires? The wire harness.

It's like the car's nervous system. Right. It connects absolutely everything. And it faces constant movement, vibration, potential abrasion. Ensuring its long-term durability is absolutely paramount. That's a critical point. I mean, if the wiring goes, everything goes. Pretty much, yeah.

So for the wire harness, especially around connectors or where wires pass through bulkheads, a high-performance thermoplastic polyamide, like Technomel P.A. 638 black, can be used. It's applied using a technique called low-pressure molding. This allows you to completely encapsulate fragile components, like connector pins or sensors integrated into the harness without damaging them. That's because the material has a low viscosity. It flows very easily at low pressure and sets, quickly to form a tough, protective shell.

Gentle but strong protection. Exactly. There are also rapid UV-curing polyacrylate potting products, like all-feet-tight AA-5-832. These are silicone-free, which is sometimes a requirement, offer excellent adhesion to typical harness materials, and are highly resistant to heat up to 150C, and also ATF-resistant. Ideal for protecting connectors and splices,

especially in challenging areas like the engine bay. Okay, wow. So we've seen these incredible materials working hard, and specific car components, cameras, radars, displays, sensors, wires. But maybe let's take a step back again. What are the foundational types of solutions, the main categories that make all this possible? Right. We can group them.

What's fascinating, and maybe the biggest driver overall, is thermal management solutions. The sheer necessity of moving heat away from critical components. It's just vital for reliability and longevity. Think about any computer chip working hard, it gets hot. If that heat isn't managed effectively, the chip slows down. or worse fails prematurely. Yeah, we've all felt a hot laptop.

Exactly. Same principle, but often in much harsher conditions in a car. So Henkel offers a really broad portfolio here. Things like liquid gap fillers. These are like thermal paste, but designed to fill larger, uneven gaps between components and heat sinks. There are curable thermal gels that are soft and conformable, but transfer heat well. And then custom die-cut GP pad materials or sill-out pad materials,

which are pre-formed thermal pans cut to specific shapes, easy to apply, assembly, for example, Bergquist Gapfeller TGF 4,400 LVO. It's a two-component silicone-based liquid thermal interface material. It boasts of 4.4 watts per meter Kelvin thermal conductivity that's pretty high, meaning it moves heat very efficiently. And it's designed for fast, robust dispensing and automated lines. Okay, so a whole suite of ways to tackle heat. Then bonding and connecting solutions.

When it comes to sticking things together in a car, failure is definitely not an option. from structural bits to tiny sensors relies on these connections holding firm. Indeed, you absolutely need strong, reliable interconnections for long-term performance under stress. And this category is huge. It includes things like those active alignment adhesives we mentioned for cameras would precisely position tiny optical components. Electrically conductive adhesives or ECAs, which actually conduct electricity, essentially allowing current to flow through the bond line itself,

useful for grounding or attaching certain components. So the glue itself is part of the circuit? In some cases, yeah. Then you have the workhorse structural bonding adhesis for robust connections, like body panels or battery housings, instant bonding adhesus, sinoacrolids or super glues, but highly specialized versions for rapid assembly of small parts, conductive inks for printing circuits directly onto substrates,

dye attach adheses specifically for mounting semiconductor chips onto packages or boards, and those liquid optically clear adhesives, LOQA's like the Loctite AA-866. 71 PSAED, we talked about for displays. It turned into a pressure sensitive esive after UV cure, which can aid assembly. Another example for active alignment, a blocktight able stick NCAA NCAA. It's a dual cure adhesive, high T, low CTE, very low outgassing. And it even comes in a gray color sometimes, specifically to prevent any stray light from penetrating, which is crucial for sensitive optical sensors.

Wow, that's a lot of different ways to stick things together. Okay. Third category. Protecting and sealing solutions. So beyond just heat, what I'm not. also we're protecting these delicate electronics from inside a car. It sounds like a battlefield in there sometimes. It really can be. You're protecting them from the entire environment, basically. Yeah. Stray electromagnetic waves, or EMI, like we discussed, extreme thermal stresses

from temperature swings, moisture, humidity, roads, salt, dust and dirt, corrosive chemicals like oils or cleaning fluids, and of course mechanical shock and vibration from just driving down the road. All of these can compromise performance or cause outright failure. So these materials safeguard electronics at all levels from the individual chip to the entire module. So what falls under this protection umbrella? A wide range. EMI protection materials that includes some thermal interface materials that also shield, like that gap pad we mentioned, but also specialized gaskets and coatings designed purely

to block electromagnetic interference. Gasketing and sealing materials, like those formed in place, if e.g. and cure-in-place, CIPT gaskets, that create custom seals against moisture and dust. Those low-pressure molding materials like Technomelph that encapsulate components, underfills like the Loctite Echobond UF 101.73 that reinforce solder joints against vibration and thermal shock. Potting materials of both thermal and standard that completely encapsulate components for the ultimate protection against shock, vibration, and fluids. And finally, conformal coatings, thin, protective polymer layers applied over entire circuit boards to shield them from moisture, dust, and chemicals. That gap pad that absorbs EMI, the Bergkiss Gap Pad, TGP-EMI 4,000, sounds like a perfect example of a material doing double duty for protection.

It absolutely is. A great example of a material synergy. It combines that solid 4.0WMK thermal conductivity with, get this, 86 decibels of EMI absorption at 18 gigahertz. That's a significant level of electromagnetic shielding. For underfills, that Loctite Echobond U.S. Keni 10173 we mentioned is crucial for reinforcing solder joints in tiny tip-scale packages. CSP and bowl grid arrays, BGA, those are common types of surface mount microchips ensuring their long-term reliability under stress. And for low-pressure molding, that TechnoMelt PA 638 black really simplifies assembly and protects fragile components beautifully, like we highlighted with a wire harness connectors. Okay. We've peeled back quite a few layers today, I think, revealed this incredible, almost hidden

world of advanced materials that are quietly enabling the whole automotive revolution right under our noses, or rather, under the hood and dashboards. from stopping critical parts from overheating to ensuring sensors line it perfectly to protecting everything against the harsh road conditions. These specialized chemical solutions are truly the silent powerhouses behind modern vehicle performance, safety, and connectivity. It's really remarkable when you stop and think about it. How these often unseen chemical solutions contribute so much to the seamless, smart, and safe experience you have every single time you drive. Hopefully it provides that kind of aha moment, understanding the hidden heroes, the material, working tirelessly inside your vehicle.

Absolutely. So the final question then. What does this all mean for the future? We know vehicles are becoming even more autonomous, more connected, more electrified. The demands on these materials must be just skyrocketing, right? Consider that constant, relentless push for materials that are not just incrementally better,

but maybe even revolutionary, in their ability to manage ever-increasing heat loads, ensure flawless high-speed connections, provide unwavering protection, all in ever smaller, letter, more complex packages. How will this continuous race for innovation in material science continue to redefine what's even possible in automotive design and function, maybe even just in the next five or ten years? Something to think about.