Homepage Article E-Mobility development through adhesives and sealants

E-Mobility development through adhesives and sealants

04/05/2026

E-mobility is now more than just a question of electrification : it is about choosing the right materials and components to support the transformation of the automotive industry. By enabling cleaner energy use in everyday vehicles and devices, batteries have become the heart of innovation and technological progress.

From electric vehicles to hybrid systems, battery performance directly impacts safety, efficiency, durability, and driving range. Behind these performances lies a complex assembly of cells, modules, and packs that must withstand demanding conditions such as vibration, thermal stress, moisture, and chemical exposure.

Adhesives and sealants play a crucial role in this ecosystem. They ensure structural bonding, thermal management, electrical insulation, and protection against aggressive substances such as electrolytes. Whether used in cylindrical, prismatic, or pouch cells, these materials help improve reliability while supporting lighter and more compact battery designs.

Cells types

Inside batteries, various types of cells exist, each with different designs and specific characteristics depending on the required application.

1. Cylindrical cells

Cylindrical cells are one of the most common battery formats used in e-mobility applications, especially in electric vehicles. Their structure consists of electrode sheets (anode, separator, and cathode) that are wound into a spiral shape and inserted into a rigid metal cylindrical casing, typically made of steel or aluminum.

Such a design offers excellent mechanical stability, good thermal resistance, and strong pressure tolerance, making cylindrical cells highly reliable for demanding automotive environments.

Adhesives and sealants are mainly used to ensure the sealing of the cell and prevent leakage of the liquid electrolyte inside. Since electrolyte leakage can lead to reduced battery performance, corrosion, or even safety risks, high chemical resistance is essential. Sealants must withstand long-term exposure to aggressive electrolyte components while maintaining airtight protection.

2. Pouch cells

Pouch cells are designed using flexible laminated aluminum film instead of a rigid metal casing. Inside, the electrodes are stacked or folded and enclosed in a lightweight pouch, which allows for a very compact and space-efficient battery design.

This format offers a high energy density and lighter overall weight, making pouch cells particularly attractive for electric vehicles where space optimisation and weight reduction are critical. However, because of their flexible structure, pouch cells are more sensitive to swelling, mechanical stress, and external damage. Therefore, choosing a flexible adhesive to seal the pouch is essential.

Adhesives and sealants play a major role in sealing the pouch and protecting the liquid electrolyte from leakage, moisture ingress, and external contamination. The sealing area must remain highly reliable despite thermal cycling and internal gas generation. Strong adhesion and excellent electrolyte resistance are therefore key requirements.

3. Prismatic cells

Prismatic cells use a flat, rectangular rigid casing, usually made of aluminum or steel, with electrodes stacked or rolled inside. This design allows for better space utilization within battery packs and simplifies module assembly, which is why prismatic cells are widely used in electric vehicles.

Compared to cylindrical cells, prismatic cells offer higher packaging efficiency and can reduce the number of individual cells required in a battery pack. However, their larger size can make thermal management and mechanical stress control more challenging.

Adhesives and sealants are primarily used to seal the casing and contain the liquid electrolyte safely inside the cell. Reliable sealing is critical to prevent leakage, maintain battery integrity, and ensure long-term performance. These materials must resist electrolyte corrosion while also supporting structural stability and vibration resistance throughout the battery’s lifetime.

Electrolyte sealing

Electrolyte sealing is a critical aspect of battery manufacturing in e-mobility applications, as the electrolyte is responsible for enabling ion transfer between the anode and cathode, directly impacting battery performance and efficiency. Most lithium-ion batteries use liquid electrolytes, which are highly sensitive and can be chemically aggressive.

Any leakage of electrolyte can lead to serious issues such as reduced battery capacity, corrosion of surrounding components, safety risks, and shortened battery lifetime. In some cases, electrolyte exposure can also create fire hazards or cause thermal runaway, making reliable sealing essential for both performance and safety.

Adhesives and sealants are primarily used to ensure airtight and liquid-tight sealing of the battery cell, module, and pack. They must provide excellent adhesion to various substrates such as aluminium, steel, and laminated films, while maintaining strong resistance to electrolyte chemicals over long periods.

In addition to chemical resistance, these materials must withstand thermal cycling, vibration, pressure changes, and mechanical stress generated during battery operation. High-performance sealants help maintain battery integrity, prevent contamination, and support the long-term reliability required in modern electric vehicles.