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Industry Application

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Case Study of Silicon Adhesive: Efficient Solution for Enhancing Inductance Reinforcement of Controller Circuit Boards

2025-04-23

BackgroundIn modern electronic devices, the controller circuit board is one of the core components, and its performance stability and reliability directly affect the operational efficiency of the entire system. However, in practical applications, due to the complex and variable working environment (such as temperature fluctuations, vibrations, etc.), the inductive components on the controller circuit board are easily affected by external factors and may become loose or damaged, thereby affecting the normal operation of the entire system. Therefore, how to effectively enhance the stability of these key components has become an urgent problem to be solved. ChallengeRapid curing requirement: In order to not affect production efficiency, the reinforcement material used must be able to complete the curing process in a short period of time.Fluid characteristic requirements: The ideal reinforcement material should have good flowability so that it can evenly cover around the inductor without unnecessary diffusion due to excessive flow.Strong environmental adaptability: considering the various use scenarios that electronic products may face, reinforcement materials also need to have excellent temperature resistance and aging resistance.SolutionAfter comprehensive consideration, we have chosen SIPC 1823 silicone adhesive sealant as the solution for this project. This product not only meets all the technical requirements mentioned above, but also has received widespread praise for its unique performance advantages:Rapid solidification of Nanjing University system: Developed based on advanced Nanjing University chemical system, SIPC 1823 can achieve complete solidification in a relatively short time, greatly reducing the waiting time on the production line.Slimming of paste body: This product presents a state between liquid and solid – paste body sagging, which ensures sufficient fluidity to adapt to inductance components of different shapes and sizes, while avoiding waste problems caused by excessive flow.High transparency and environmental friendliness: In addition to excellent physical performance, SIPC 1823 also has extremely high transparency, which…

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Elaplus shares the sealing of car vent tank connectors

2025-04-23

In the automotive industry, the pneumatic system (commonly known as the “vent tank” or energy storage tank) is a key component that ensures the overall power response and smoothness of the vehicle. The inside of the vent tank often needs to maintain a high pressure of 35-40 Bar and withstand a wide temperature cycle test from -40 ℃ to 100 ℃. And the various connectors (sensor interfaces, solenoid valve interfaces, etc.) directly connected to the tank are the “throat” of the entire system: once the seal fails, it will cause air pressure leakage, system failure, and even endanger the safety and stability of the entire vehicle in severe cases. Therefore, selecting the appropriate sealing material for the automobile vent tank connector has become a technical challenge that vehicle manufacturers and component suppliers must focus on overcoming. 1、 Project BackgroundApplication scenariosComponent location: Gas tank assembly near or on the chassis of the vehicle;Working medium: Vehicle mounted high-pressure nitrogen or compressed air;Work pressure: 35 Bar to 40 Bar (normal operating and safety reserve pressure);Temperature range: -40 ° C (starting in cold conditions) to -100 ° C (engine compartment high temperature superposition);Vibration and impact: The combination of road bumps and engine vibrations during vehicle operation.Project objectivesEnsure that the connector is sealed without leakage under the long-term action of high-pressure gas;Maintain reliability even after meeting extreme high and low temperature cycles;Realize rapid solidification and improve production efficiency;Control material and process costs to meet the requirements of mass assembly of parts.2、 Main challenges

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Case Study on Thermal Insulation Sealing of Control Box: Low Cost, High Performance Thermal Management Solution

2025-04-23

📘 Case backgroundIn today’s rapidly developing era of intelligent manufacturing and industrial automation, electrical control boxes, as key electronic integration modules, are widely used in various fields such as rail transit, power systems, new energy equipment, industrial robots, etc. The control box integrates a large number of power modules, control chips, sensors, and power devices inside. These components will continue to generate heat during long-term operation, leading to module temperature rise and affecting its stability and service life. In order to ensure the long-term stable operation of the control box in harsh environments, sealing glue is often used to protect it. It not only plays a role in waterproofing, dust prevention, and shock resistance, but more importantly, it provides thermal management function to timely dissipate the heat generated during device operation, reduce thermal accumulation, and avoid device overheating and failure. In the client’s project, a control box for an industrial automation equipment needs to undergo thermal conductive sealing treatment. The main requirements of the customer for sealing materials are as follows:Thermal conductivity: 0.6~0.8 W/m · K, meeting the needs of daily industrial use;Moderate viscosity: has good fluidity and can fully fill the gaps inside the control box;Good electrical insulation: Ensure that it does not affect the operation of the circuit after encapsulation;After curing, it has a certain degree of flexibility: to avoid stress concentration caused by thermal expansion and contraction; The most important point is to control the cost within 20 yuan/kg and have the conditions for large-scale use. Control box thermal conductivity sealing ⚠️ Challenges FacedDuring the material selection process, customers faced the following challenges:one ️⃣ It is difficult to balance the thermal conductivity and cost of materialsTraditional high thermal conductivity sealing materials, such as silicone systems or epoxy systems with abundant fillers, although their thermal conductivity can reach…

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Application of EP 2029A/B epoxy adhesive in the bonding and sealing of thermistor and housing

2025-04-18

In modern electronic devices, thermistors are a key component that can sense temperature changes and provide feedback on resistance changes. They are widely used in fields such as home appliances, power equipment, motors, and automotive electronics. In order to ensure the long-term stable operation of the thermistor, its adhesion and protection to the housing are crucial. EP 2029A/B epoxy adhesive, as a two-component structural adhesive with excellent mechanical properties and chemical stability, is an ideal choice for playing an important role in the fields of thermistor encapsulation and shell bonding.Background: The Importance of Bonding Thermistors to the Shell.

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Elaplus Case Study/Application of adhesive to pressure sensor

2025-04-11

In modern industrial manufacturing, pressure sensors are widely used as key detection components in fields such as automotive, aerospace, medical equipment, and industrial automation. However, these high-precision devices have extremely demanding requirements for material selection and processes, especially in the application of adhesives.We will discuss two adhesives that are particularly suitable for the production of pressure sensors – SIGEL 1806 for gel encapsulation and EP 1738 for shell bonding, and show how they can help enterprises improve product quality and production efficiency through specific cases.Demand for gel pottingThe internal circuit board of the pressure sensor requires a sealing material that can provide protection to prevent damage to sensitive components from external environments such as humidity, dust, vibration, etc. At the same time, the sealing material must have low stress characteristics to avoid damaging precision components due to mismatched thermal expansion coefficients.The difficulty of shell bondingThe housing of a pressure sensor is composed of two materials: metal and plastic. Traditional adhesives are difficult to achieve strong bonding and require stability under extreme conditions of high and low temperatures. In addition, the customer wishes to simplify the production process and reduce the curing time.Customized solution: Double material combination solves technical problems After on-site testing by our technical team, a targeted combination solution of “sealing+structural bonding” has been proposed:▶ Core protective layer: SIGEL1806 gel potting adhesiveInnovative low modulus formula (penetration degree 70) effectively absorbs mechanical stressMaintain elasticity over a wide temperature range of -60 ℃ to 200 ℃3D stereoscopic coating technology achieves “zero damage” protection for sensitive componentsThixotropic index>4.5, no sagging during vertical surface construction, and the sealing qualification rate has been increased to 99.2%▶ High strength adhesive layer: EP 1738 epoxy adhesiveSingle component thermosetting design (120 ℃/60min), increasing production line efficiency by 40%Shear strength>18MPa, according to MIL-STD-810G vibration standard Chemical resistant properties:…

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Elaplus Case Study on Thin Layer Sealing of Automotive Oil Pump PCB

2025-04-07

In the wave of intelligentization in the automotive industry, electronic control systems are becoming the “nerve center” of vehicle operation. As the core execution unit of the fuel supply system, the fuel pump controller PCB has long faced extreme challenges under harsh operating conditions: high-temperature roasting at 120 ℃ in the engine compartment, gasoline vapor erosion, and continuous mechanical vibration… all of which are threatening the reliable operation of electronic components. How to build all-weather protective barriers for critical circuits? The Wave of Automotive Electronics and the Challenge of PCB EncapsulationWith the development of intelligent and electrified automobiles, electronic control systems have become the core components of modern cars. From engine management systems to battery control units for new energy vehicles, precision printed circuit boards (PCBs) work continuously in harsh environments such as high temperatures, vibrations, and humidity, and their reliability directly affects the safety and durability of the vehicle. However, the application of PCBs in key components such as automotive oil pumps faces the following challenges:Adverse environment: Complex working conditions such as high temperature, high humidity, oil pollution, and vibration require extremely high protection for electronic components.High reliability requirement: Electronic component failure may lead to oil pump failure, which in turn can cause vehicle power system paralysis or safety hazards.Environmental Protection and Regulatory Pressure: Global environmental standards for automotive components are becoming increasingly strict, and the problems of solvent residue and heavy metal pollution in traditional sealing materials urgently need to be addressed.Recommended product: PUR 1627A/B two-component polyurethane sealantPUR 1627A/B is a two-component solvent-free room temperature or heat cured resin elastomer composite used in two-component sealing, filling, flame retardant, thermal conductivity and other fields. The raw materials are free of heavy metals, environmentally friendly, and have a wide range of process operability. The finished product has high physical properties…

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Automotive electronic steering wheel hands-free sensor PCB protection

2025-04-07

Application background: PCB protection challenges in the era of automotive electronicsWith the rapid development of intelligent driving technology, automotive electronic systems are undergoing a comprehensive upgrade from traditional mechanical control to intelligent and digital direction. Among them, the Hand Off Detection Sensor, as a key component of Advanced Driver Assistance Systems (ADAS), plays an important role in monitoring whether the driver has released the steering wheel and ensuring driving safety.However, these precision electronic components face multiple challenges in practical applications:Strict environmental conditions: The interior space of the car is narrow and exposed to complex environments such as vibration, high temperature, humidity, salt spray, etc. for a long time;High reliability requirements: Sensors, chips, and circuits on PCB (printed circuit board) must maintain stable performance under extreme working conditions;Lightweight and space limitations: Adhesives need to balance sealing, fixing, and shock absorption functions while avoiding additional weight or space occupation.For this scenario, PUR 1680 polyurethane adhesive has become the preferred solution for automotive electronic PCB protection due to its excellent comprehensive performance.Solution – PUR 1680 polyurethane sealant breakthrough advantagePUR 1680 A/B is a two-component solvent-free room temperature or heat cured resin elastomer composite used for two-component sealing and filling. The raw materials are free of heavy metals, environmentally friendly, and have a wide range of process operability. The finished product has high physical properties and good adhesion to the substrate. It can be cured at room temperature or by heating, and can be deeply cured. The two-component mixture has good fluidity and excellent flexibility after curing. It is used for casting and sealing of communication equipment, transformers, control power supplies, ignition controllers, electronic sensors, etc. Low 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…

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Elaplus Case Study on Waterproof and Airtight Protection of Automotive Integrated PCB

2025-04-07

Against the backdrop of rapid development in automotive electronic applications, automotive integrated PCBs, as the core carrier of electronic products, are facing increasingly stringent environmental challenges. How to ensure that PCBs can maintain stable working conditions even when exposed to external factors such as moisture, dust, chemical corrosion, and mechanical impact has become a key concern for engineering and manufacturing personnel. For this reason, Yilian chose RTV SIPC 1859 dealcoholized silicone adhesive sealant as the solution. Through its application in PCB frame sealing and buckle fixing, it successfully built a sturdy waterproof, airtight, and mechanical protection barrier for automotive electronic systems. Waterproof and airtight protection of automotive integrated PCB With the continuous improvement of automotive intelligence and electronic system integration, automotive integrated PCBs play a crucial role in key components such as in vehicle networks, sensors, and control units. However, during the operation of automobiles, integrated PCBs often face severe challenges in the following aspects:Waterproof and airtight requirements: During driving, cars not only need to deal with the invasion of rainwater, car wash water, and humid environments, but also need to prevent water vapor and dust from entering the interior through the gaps of the PCB shell, which can cause corrosion and damage to the circuit board and components.Frame sealing and buckle fixation: To ensure the sealing effect, the PCB frame must be tightly sealed; Meanwhile, enhancing the stability and seismic resistance of the overall structure through buckle fixation is a necessary means to ensure the normal operation of electronic products in complex environments such as vibration and thermal shock.Environmental adaptability: The working temperature range of automotive integrated PCBs is usually wide, and stable mechanical and electrical properties must be maintained from low temperature environments (-60 ℃) to high temperature environments (300 ℃). Sealing materials are required to have excellent…

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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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