1.
MAHMOUD AWWAD, NOVEMBER 2022
MATERIAL SOLUTIONS
FOR EV CHARGING
INFRASTRUCTURE

2.
AGENDA
2
TOPICS
01 Introduction
02 Challenges / Expectations
03 Trends / Future
04 Materials Solutions
05 Conclusion

3.
MAHMOUD AWWAD
INTRODUCTION
3
Business Development Manager, Power Conversion & Industrial Automation,
Henkel Industrial Adhesives
▪ With Henkel Adhesive Technologies since 2008
▪ Based in Utrecht area, the Netherlands
▪ 15 years of serving customers in multiple markets including Industrial
Automation, Power Conversion, Automotive, Medical and Power Electronics

4.
€2.7BN
ADJUSTED OPERATING
PROFIT (EBIT)
SALES
€20.1BN
WE ARE ACTIVE IN
79COUNTRIES
145YEARS
SUCCESS WITH
BRANDS AND
TECHNOLOGIES
AROUND
38%
WOMEN IN
MANAGEMENT
-50%
LESS CO2 EMISSIONS
PER TON OF
PRODUCT1
WE EMPLOY MORE THAN
52,000
PEOPLE WORLDWIDE FROM
124 NATIONALITIES
4
¹ Figure relates to the 2021 fiscal year compared to the 2010 base year

5.
CHALLENGES IN EV
CHARGING INFRASTRUCTURE
5
Consumer Expectations
SAFETY
Critical and non-negotiable. Safety agencies ubiquitous.
TOTAL COST OF OWNERSHIP
Capital cost will be important as many units purchased by
local utilities and consumers remain sensitive .
RELIABILITY
Available chargers expected to work. Harsh environments
and public installations. Product life.
CHARGING SPEED
Customers expect to charge in short time. Destination
charge is not always reasonable or desired
ACCESIBILITY
Until charging is abundantly available, across provider
access and charger uptime is paramount

6.
CONVERGENCE OF ENERGY & INTERNET
Systems, Data, Optimization, and Security all lead to more
computational and communications overhead
HIGHER POWER
As battery voltage and charge speed expectations increase,
power will naturally follow
TRENDS IN EV CHARGING
INFRASTRUCTURE
6
Innovation and Future Needs
HIGHER EFFICIENCY
Legislation, Corporate Citizenship and TCO drive for more
energy efficient solutions.
INCREASED ENVIRONMENTAL AWARENESS
Grid Citizenship, Legislation, Efficiency, Waste, and Reliability
all play into this key trend
STANDARDIZATION
Important for accessibility, safety, and total cost of
ownership. Drives an expected experience

7.
7
▪ Result of
– Higher charging speed
– Increased function
– Higher voltage
– Higher current
– Wide Band Gap
▪ Thermally conductive potting
▪ Thermal interface materials
▪ Solid insulating materials
HIGHER POWER IN EV CHARGING

8.
8
▪ Driven by:
– Consumer anxiety
– Harsh environments
– Increased temperature
– Outdoor exposure
– Impact & vandalism
– Temp cycles
▪ Gasketing & sealing solutions
▪ Conformal coating
▪ Connector potting
▪ Thermal interface solutions
RELIABILTY IN EV CHARGING

9.
HENKEL MATERIAL SOLUTIONS FOR
EV CHARGERS
9
Overview
Application Technology Level 1 Level 2
Level 3 /
Ultra-fast
Thermal
Thermally Conductive Insulating Films
(Sil Pad, Hi Flow) ✓ ✓ ✓
Gap Filling Materials (GAP PAD, Gap Filler) ✓ ✓ ✓
Phase Change ✓ ✓ ✓
Protecting
Potting (charging guns) ✓ ✓ ✓
Conformal Coatings ✓ ✓ ✓
Gasketing / Sealing ✓ ✓ ✓
Bonding
Thread Locking Adhesive ✓ ✓ ✓
Staking Adhesives ✓ ✓ ✓

10.
CONTROLLING THERMAL
CONDITIONS FOR DC FAST
CHARGING RELIABILITY
10
CHALLENGES
Phase change material on a power
module system converter board
SIL PAD material on a discrete
component system converter
board
▪ Building out a fast-charging EV infrastructure demands a return
on investment via reliable systems that prioritize durability,
performance and safety.
▪ A major concern with DC fast and ultra-fast chargers is their
voltage levels that range from 400V to over 1000V and power
that can be in excess of 350kW.
▪ To control the heat generated by such high-power transfer,
system designers must employ highly-effective thermal
management strategies to maintain consistent and reliable
power delivery, both for the charger and the battery pack.
SOLUTIONS

11.
PROTECTING ELECTRONICS
IN EV CHARGING DEVICES
11
CHALLENGES
Applicable to EV chargers of all levels, especially those positioned
outdoors, Henkel’s Sonderhoff formed-in-place-foam-gasket (FIPFG)
technology provides a comprehensive equipment and high-reliability
material combination.
SOLUTIONS
▪ Because the chargers may require service, gasketing materials
used to secure the housing structure should provide a tight seal
to keep out dust, moisture and corrosion, while allowing access
for serviceability. The gaskets need to offer long-term
protection, withstand temperature fluctuations, cope with heat
generated by electronic components, and resist degradation
from outdoor exposure.
▪ High automation capability to facilitate high volumes
(residential and commercial chargers), as well as manage large
designs (DC fast charging stations) and various closure
geometries will provide manufacturing flexibility, design
modification adaptability and reduced production costs.

12.
BUILDING DURABILITY INTO
EV CHARGING CONNECTORS
12
CHALLENGES
Henkel’s portfolio of UL-rated potting materials offers a range of
formulations with different chemistry platforms, cure schedules and
flexible pot life timelines. Proven in numerous applications, these
materials are well-suited for the demands of EV charging connectors.
SOLUTIONS
▪ To protect and strengthen the connector assembly, potting
material is dispensed inside the charger handle, covering and
encapsulating all of the cables and components, and adhering
to the interior of the case. Strong adhesion to all surfaces –
plastics, wire and component coatings -- is essential.
▪ To accommodate high-volume production speeds, the potting
material should dispense and cure quickly, with no leakage so as
to ensure ample material for protection of interior components.
Balancing material viscosity with lower gel times is advantageous.
▪ UL 94 flammability certification for defense against fire from
high thermal loads, as well as moisture and dust resistance for
ingress protection, are key to meeting charger performance
expectations.

13.
CIRCUIT-BOARD PROTECTION
FOR SYSTEM-LEVEL RELIABILITY
13
CHALLENGES
Henkel conformal coatings ensure electronic operational integrity by
defending electronic circuits from thermal shock, dust, moisture and
dynamic environmental conditions. Simple to apply and process, these
SVHC, solventless, tin-free formulas are UV and moisture cure capable
for optimized sustainable protection
SOLUTIONS
▪ As global electric vehicle (EV) volumes continue to grow, the
need for reliable charging devices is front and center.
▪ Consumer satisfaction with the EV experience will largely be
driven by cost, convenience and charging device reliability –
both at home and on the road.
▪ For chargers of all power levels – from level 1 to level 3 -
protecting the internal electronics from environmental
contaminants helps keep them operating as expected.

14.
SUSTAINABILITY IN EV CHARGING
14
Leading Driver for
Adoption
▪ Primary driver for early
consumers to adopt EV
▪ Sustainability is a
valuable goal on its own
merit, but also
resonates with
customers and
shareholders
▪ Materials choices in
designing and
manufacturing charging
solutions can have a
significant impact on
scope 1, 2, and 3
emissions

15.
15
HENKEL SOLUTIONS FOR EV CHARGING INFRASTRUCTURE
AC charging versus DC charging
On-board versus Off-board equipment

16.
CONCLUSION
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▪ EV vehicles be comparable with fuel-based vehicles in
terms of charging max. 10 mins
▪ Public charging stations will need to be installed rapidly
to keep up with demand and multi-household
infrastructure
▪ Ecosystems for EV infrastructure need to develop in
order to support the grid resilience and ensure grid
stability (energy storage could be a solution here)
▪ Comfort will play a critical role for further EV adaption -
range anxiety changed into charge point and charge
time anxiety

17.
THANK YOU.
17