The large mass of batteries limits the efficiency of electric vehicles. Increasing capacity extends the range, but at the same time worsens handling and energy consumption. Until solid-state batteries reach mass production, manufacturers are looking for other ways to optimize.
Two materials instead of one
Mercedes-Benz proposes to reconsider the design of the battery pack. A new method of module mounting is described in a patent (USPTO No. 12614774, published in April 2026).
Instead of using screws, brackets, or a single universal adhesive, the company divides functions between two materials. Each performs its own task.
The first layer of adhesive is located under the module. Its main role is to conduct heat away from the cells to the battery case. At the same time, it fixes the module in the base position.
The second type of adhesive is applied to the sides. It is responsible for mechanical strength and holds the module under loads during movement.
Fewer fasteners - less weight
In traditional designs, one fastening system performs two functions simultaneously: provides rigidity and participates in heat dissipation. This requires either massive mechanical elements or a significant amount of adhesive.
Task separation allows for more efficient use of materials. In particular, the lower layer of adhesive can be thinner, as it does not bear the main mechanical load. This directly affects the weight of the battery pack.
Simpler design and maintenance
The scheme presented in the patent provides for a "tray" type case. Modules are installed on a base surface and secured on the sides. This approach reduces the number of parts and simplifies assembly.
There is also a practical advantage for maintenance. The side adhesive is rated for strength but can be cut. This means that an individual module can be replaced without complete disassembly of the battery - this is often more difficult today.
More stable battery operation
Improved heat dissipation is another important effect. More efficient cooling allows the cells to work more stably under load and potentially extends their lifespan.
