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Industry Application

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Potting Compound for Automotive Connector

2025-04-01

Automotive connectors are an important component of automotive electronic systems, mainly used to transmit electrical signals and power, ensuring stable connections between various electronic devices. They are designed to be compact, durable, and have features such as waterproof, dustproof, and shockproof to adapt to complex in car environments. Widely used in engine management, vehicle electronics, intelligent driving and other fields, automotive connectors play a key role in ensuring vehicle safety and high-performance operation.What is connector encapsulation?The sealing process refers to the use of epoxy adhesive, resin, or other similar compounds to fill a certain area into a hard and stable state, thereby forming an effective barrier. In the field of connectors, the encapsulation process is usually used on the back of the connector, which is called back encapsulation. Its main purpose is to enhance the overall firmness of the connector, improve retention force through encapsulation, ensure a more stable connection, and provide additional protection for cables and contacts.The main protective function of connector encapsulation compoundsWaterproof: Block moisture penetrationCorrosion resistance: resist chemical corrosionAnti wear: Extend service lifeHigh temperature resistance: to cope with hot environmentsThermal shock resistance: resisting the effects of sudden temperature changesAnti vibration: maintain stable connectionResistance to mechanical impact: providing additional structural supportThe best time to use connector encapsulation and protective coatingConnector back design: Typically designed with retaining walls or extension walls to accommodate liquids when the potting compound solidifies.Cover protection: Cable connectors are generally equipped with a cover, and sealing can be carried out inside the cover to enhance overall protection.Temporary retaining wall: A temporary retaining wall can be built around the rear of the connector to ensure that the sealing compound does not overflow during the curing process.Special layout: For situations where not all contacts are wired, designing appropriate encapsulation channels can help the compound flow through the…

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Lithium battery hard pack PACK application: square battery solder joint protection and aluminum shell blue film back adhesive solution

2025-03-31

Against the backdrop of global energy transition and rapid development of new energy vehicles, the application of lithium batteries as core energy storage technology is becoming increasingly widespread. Especially in hard pack (or soft pack) PACK systems, square batteries have become one of the mainstream. Their high energy density, long cycle life, and high safety have made them widely used in fields such as electric vehicles (EVs), energy storage, and consumer electronics. However, with the increasing demand for applications, lithium batteries also face many technical challenges in production, use, and maintenance, especially in terms of solder joint protection and shell sealing. Classification and challenges of lithium batteriesLithium batteries can be mainly divided into the following types:Cylindrical batteries: commonly found in consumer electronics and some small and medium-sized power tools. Its structure is simple, the production process is mature, and it can provide good stability.Square battery: commonly used in electric vehicles (EVs) and energy storage devices. The advantages of square batteries are high energy density, customizable volume, and compact structure, making them suitable for large-scale battery pack applications.Soft pack battery: It has a wide range of applications in the field of electric vehicles, especially in some high-end models. It adopts flexible packaging, which can improve the design flexibility of battery packs to a certain extent, reduce volume and weight.Although square batteries perform well in many applications, they also face some technical challenges in practical use, mainly reflected in solder joint protection, aluminum shell packaging, and issues such as high temperature and vibration that the battery may encounter during use. If these challenges are not properly addressed, they may affect the safety, reliability, and lifespan of batteries.Challenge: Protection of solder joints in square batteries In the PACK design of square batteries, solder joints are important parts for connecting the various units inside…

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Elaplus sealing for junction box with organic silicon CIPG

2025-03-31

In the fields of new energy, power electronics, automobile manufacturing, etc., junction boxes, as the core protection unit of circuit systems, have long faced problems such as waterproof failure, insulation degradation, temperature difference deformation and cracking. Traditional sealing materials are difficult to meet the requirements of complex working conditions due to poor weather resistance and insufficient bonding strength. How to choose a solution that combines long-lasting sealing, stable insulation, and extreme environmental resistance? Glue requirements1： CIPG2: Plaster thixotropy3: Waterproof and insulatedRecommended productsElaplus SIPA 1820 is a paste thixotropic single component silicone adhesive that is heat cured, environmentally friendly, non-toxic, and easy to use. After curing, it forms a silicone elastomer with excellent high and low temperature resistance, weather resistance, electrical insulation performance, as well as excellent waterproof, earthquake resistance, absorption of expansion and contraction, corona resistance, and leakage resistance. Specially designed to provide long-lasting thermal stability bonding for various metals, glass, silicone rubber, plastics, mica sheets, and ceramic substrates.Product characteristics■ Temperature resistance -60 ℃~+280 ℃Single component thixotropic paste, fast heating and curing■ Can bond a large number of substrates without the need for a primer■ Has excellent flexibility and tear resistance■ Additive curing system: no curing by-products■ ROHS/REACH certifiedTypical applicationsAdhesive bonding between plastic shell and aluminum plateSealing of steam chamber for electric ironElectric vehicle water pump seal■ Motor control box CIPG■ Bonding of heating elementsIn emerging fields such as smart grids, energy storage systems, and 5G base stations, Elaplus SIPA 1820 is becoming the trusted choice for engineers to cope with harsh environments with its three in one performance matrix of “sealing insulation protection”. Free sample application and customized process plan * * are now open. Click on the official website or scan the code to obtain the technical white paper.label: CIPG Sealing Solution · Junction Box Sealing · New…

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Industrial sensor probe wire harness encapsulation: PUR 1670 is designed for harsh high and low temperature environments

2025-03-31

In fields such as industrial automation, automotive electronics, and new energy, sensors serve as the “nerve endings” for data acquisition and system control, and their reliability directly determines the operational efficiency and safety of equipment. As the core carrier of signal transmission, the sensor probe harness is exposed to complex environments such as vibration, temperature difference, humidity, and chemical corrosion for a long time. How to achieve long-term sealing protection of the harness through encapsulation technology has become a key focus of industry technological research.1、 Industry pain point: The rigorous challenge of PVC wire harness encapsulationPolyvinyl chloride (PVC) is widely used as an insulation layer for industrial sensor wiring harnesses due to its low cost, good flexibility, and corrosion resistance. However, traditional potting materials often face the following challenges when bonding PVC substrates:Insufficient adhesion: Long term vibration or bending of the wire harness can easily cause delamination between the adhesive and PVC, leading to sealing failure;Poor temperature adaptability: Colloids become brittle and crack at extreme low temperatures, and soften and deform at high temperatures, making it difficult to meet the industrial requirements of -40 ℃~85 ℃;Weak impact resistance: The thermal expansion and contraction stress caused by equipment start stop or sudden environmental changes accelerates the cracking of the sealing layer.These issues not only affect the stability of sensor signal transmission, but may also cause equipment failures or even safety accidents. Therefore, a sealing adhesive that combines strong adhesion, wide temperature range stability, and impact resistance has become an urgent need in the industry. Why do we need high-quality potting materials?In industrial applications, sensor probe harnesses are typically exposed to various harsh environments, including high and low temperatures, humidity, vibration, and chemical corrosion. These external factors can easily cause the wiring harness to age, crack, or detach, thereby affecting the normal…

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Elaplus case sharing of Sealing Scheme for DC Contactor

2025-03-31

In the field of industrial manufacturing, DC contactors are widely used as key electrical components in new energy vehicles, rail transit, wind and photovoltaic power, and energy storage systems. However, with the increasing complexity of application scenarios, DC contactors have put forward higher requirements for packaging materials: not only should they have excellent high temperature resistance, but they should also be able to effectively flame retardant and resist stress cracking caused by drastic temperature changes. In response to these stringent requirements, we are pleased to introduce two high-performance epoxy potting adhesives – EP1735 single component epoxy and EP1780 two-component epoxy, which have become your best choice with excellent comprehensive performance. Whether it is a new energy vehicle battery management system or a wind power generation equipment, DC contactors often need to operate for long periods of time in high temperature environments. This places extremely high demands on the heat resistance of the sealing material.Basic requirements: high temperature resistance, flame retardancy, and temperature shock resistanceAdhesive substrate: PA、PPS、 Copper nickel plating, copper silver plating. Recommended productsEP 1735One part epoxyHigh adhesive strengthGood high-temperature resistance effectEP 1780Two part epoxyLow coefficient of linear expansionHigh bonding strength, thermosetting to improve temperature resistanceTags: Epoxy Sealing Adhesive · DC Contactor Sealing

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Application of Elaplus Adhesive in Automotive Regulators

2025-03-31

What is a car motor regulator?The power supply system of a car is composed of a car battery and a generator. The generator is responsible for charging the battery and keeping it in a fully charged state for a long time. The battery and generator are responsible for supplying power to the electrical appliances of the entire vehicle. Due to the fact that the generator is driven by the car’s engine, and the engine speed is not constant, it can cause the output voltage of the generator to decreaseInstability requires an electronic device to control the generator, so that the generator can output a relatively stable voltage at different speeds of the car engine.In addition, when the generator is charging the battery, it is necessary to prevent excessive charging current, and this electronic device also needs to have a current limiting function.The rotor is first energized to generate a magnetic field;The rotation of the rotor can generate three-phase AC power in the statorThe rectifier converts three-phase AC power into DC powerVoltage regulator controls the magnetic field of the rotor to regulate the generator voltageFunctional requirements of adhesive for automotive motor regulators The main function of the regulator is to achieve stable control of the generator voltage, usually focusing on electrical insulation and the high and low temperature resistance of the product; Require the adhesive to maintain good electrical stability even under various simulated testing conditions after curing.Focus on adhesive performance:

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How to use PUR 1680 polyurethane encapsulation to solve the key problem of power tool control board

2025-03-31

The reliability of the control board is crucial in the design and manufacturing of modern electric tools. The durability and protection of the control board directly affect the performance and service life of the tool. Especially in harsh environments such as high temperature, humidity, and vibration, special protective measures are required to prevent potential damage to the control board. In this context, polyurethane encapsulation (PUR 1680) has become an ideal choice for ensuring the stability and long-term reliability of power tool control boards. Challenges faced by power tool control boardsAs a high load, high-frequency operation equipment, the control board of electric tools must be able to withstand long-term vibration, impact, and extreme working environments. The control board of electric tools not only needs to have good electrical performance, but also effectively resist external physical impacts, chemical corrosion, and temperature changes. These factors may lead to short circuits, corrosion, and even functional failure of the internal circuits of the control board. Therefore, ensuring the long-term stable operation of the control board and providing reliable protection in high demand environments is a challenge that every manufacturer must face.PUR 1680 Polyurethane Encapsulation: Ideal Protection Solution for Power Tool Control BoardsPUR 1680 polyurethane potting is a material designed to provide excellent protection for electronic components. It has various outstanding performances and can effectively solve the challenges faced by power tool control boards. The following are the advantages of PUR 1680 in the sealing application of power tool control boards:Product characteristicsLow viscosity, strong operabilityExcellent low-temperature characteristics and outstanding weather resistanceExcellent electrical insulation and stability stabilityGood waterproof and moisture-proof properties, with extremely low water absorption rateHas good adhesion to most metals and plasticsThe control board of electric tools faces multiple challenges in long-term high load and high-frequency working environments. PUR 1680 polyurethane sealing material has become…

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The challenges of bonding industrial electronic relay components and the necessity of thermal conductive adhesive

2025-03-31

In modern industrial automation and electronic equipment, industrial electronic relays play a crucial role. As one of the core components of circuit control, relays are responsible for signal transmission, current switching, and circuit protection functions. Relays are indispensable in household appliances, automotive electronics, and industrial control systems. However, with the continuous advancement of technology and the increasing complexity of application environments, industrial electronic relays are also facing a series of challenges, especially in terms of component fixation and heat dissipation management.Challenges faced by industrial electronic relaysVibration and impact cause loosenessIn scenarios such as transportation and wind power, strong vibrations may cause internal components to loosen or detach, affecting performance.High temperature operation leads to thermal failureLong term operation of relays can generate heat. If the heat dissipation is poor, it can easily lead to high temperatures, causing short circuits or contact erosion.Dampness and corrosive gas erosionHigh humidity or corrosive environments can accelerate the aging of the casing and rusting of metal components, shortening their service life.High installation and maintenance costsThe traditional mechanical fixation method is inefficient and difficult to adapt to large-scale production needs, and the maintenance cost is also high.Why do we need thermal conductive adhesive?To solve the above problems, thermal conductive adhesive has become an ideal choice:Firmly bonded to prevent looseningThermal conductive adhesive can firmly fix components, avoiding displacement and failure caused by vibration or impact.Efficient heat dissipation and improved stabilityIts excellent thermal conductivity can quickly transfer heat to the outside, ensuring that the equipment operates at a suitable temperature.Strong weather resistance and resistance to harsh environmentsAdhesive has waterproof, moisture-proof, and chemical corrosion resistance capabilities, effectively protecting relays from environmental erosion.Simplify the process and reduce costsThe use of thermal conductive adhesive can save tedious mechanical assembly steps, achieve automated coating, improve efficiency, and reduce manufacturing costs.Recommended product: Single component…

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Elaplus electrode epoxy sealing&bonding adhesive -5000V high voltage transparent adhesive, solves the problem of high voltage sealing!

2025-03-20

Is your electrode sealant still failing due to high voltage breakdown? Does ion permeation cause performance degradation In the field of precision electronic packaging, an epoxy adhesive that meets the requirements of ultra-high voltage insulation, ion migration resistance, and long-term transparency is the key to winning in high-end manufacturing! The core challenge of electrode sealingThe electrode sealing adhesive needs to cope with challenges such as high voltage, high electric field, and long-term environmental aging, and the following points are particularly critical:High voltage resistance: High voltage environments above 5000V place extremely high demands on the electrical insulation performance of adhesives.Preventing ion permeation: Ion permeation can lead to a decrease in dielectric performance, affecting device reliability.Transparency and anti yellowing: Some application scenarios require maintaining high light transmittance while maintaining transparency and preventing yellowing after prolonged use.Adhesive bonding performance: The viscosity of the adhesive needs to be moderate, which can be easily applied while ensuring a firm bonding.Recommended products: EP 2005 & EP 1708In response to the above requirements, Yilian recommends two high-performance epoxy adhesives – EP 2005 and EP 1708, which perform well in electrode sealing applications.EP 2005High strength, excellent adhesionNo solvents, no solidification by-productsHas good adhesion to fiberglass cloth and steel plates, etcEP 1708Good adhesionExcellent crack resistance and toughnessConfidentiality, solvent-free, and free of solidification by-productsElectrode sealing and bonding is not just a simple bonding process, but a core link involving long-term reliability. Choose EP 2005 and EP 1708 to make your high-voltage electrode seals safer, more stable, and durable! Do you want to know more product details? Welcome to consult!Tags: Epoxy Adhesive · Electrode Epoxy bonding Adhesive

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