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Solutions for Quiet and Strong Battery Electric Vehicles

    November 28, 2018

Global automakers are making battery electric vehicles (BEV) a top priority. The key to adoption is addressing consumer demands, including comfortable, quiet interior cabins, as well as longer battery ranges which are closer inline with conventional internal combustion engines (ICEs). These market changes require acoustic and structural solutions that promote lightweight alternatives aligning with battery design requirements.

Acoustic Solutions

While BEVs will significantly contribute to reducing CO2 emissions, they will also significantly contribute to increased noise within the passenger cabin. Vehicle noises that have previously been covered up by the din of internal combustion engines (ICEs) will be more apparent to occupants. The design of BEVs presents a new conundrum for OEMs: how to reduce the impact of noise, vibration and harshness (NVH) on passengers?

With its broad portfolio of lightweight acoustic solutions, Henkel helps OEMs obtain a more structurally sound vehicle design. Henkel’s engineering center designs acoustic parts that provide NVH mitigation with lightweight alternatives, including structural adhesive patches, baffles and tapes. These solutions can be applied at BIW and other phases of production to the small gaps where vehicle, road and wind noise can seep into the passenger cabin to help reduce noise and increase structural integrity.

Learn more about enabling lightweight design with tapes and patches here

Structural Solutions

Increased performance of BEVs is tied to increase in battery weight, as batteries are getting larger to accommodate longer-range driving.

To offset the additional battery weight, lightweighting other areas of the vehicle is a top priority. Henkel provides lightweight alternatives to heavy steel inserts while meeting crashworthiness standards. Let’s explore the available options:

  • Structural adhesives – Improves the distribution of stress energy from impact to manage force energy, thereby maintaining the structural integrity needed to protect the vehicle body and battery pack. This increased load-carrying capability enables the use of down-gauged substrates in vehicle structures, which helps increase lightweight performance.
  • Structural inserts – Heat-cured, epoxy-based foam inserts act as lightweight reinforcements by filling gaps while also enhancing stiffness, NVH and section integrity by adding strength to body cavities. Applying these inserts in pillars, rails, cross members, frames, engine mounts, doors and body panels help mitigate NVH while reinforcing strength and crashworthiness. They are designed to withstand the harsh conditions of the body, trim and paint shops, and use the heat generated in these environments to expand, fill and strengthen openings in vehicle structures. In an IIHS roof crush simulation 5.4 kg of weight savings was achieved through downgauging of the A-/B- Pillar and adding structural inserts to increase structural integrity!


Combined with Henkel’s in-house design capabilities and rapid prototyping shop, the full line of acoustic and structural technologies make vehicles, lighter, stronger, quieter and safer. To learn more, watch the webcast: Enabling Lightweight Design with Tapes and Patches.

About the Author, Brooke Virost

Brooke Virost is the North American e-Mobility Business Development Manager for Acoustic and Structural Solutions with Henkel Corporation. Her technical experience ranges from managing Henkel’s adhesive portfolio in the body-in-white structural industry to leading global launches and supporting multiple OEM platforms. Previous to this role, Virost worked in mechanical engineering and quality engineering, with roles such as Launch Engineer and Design and Release engineer. Virost provides key technical knowledge for the acoustic and structural team on baffles, tapes, inserts and adhesive structural and sealing solutions. Virost received her degree in Biochemistry from Kettering University in 2015 and is currently working on an MBA from the University of Michigan.

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