How to Select Potting Compounds for New Energy Vehicle Charging Guns: ELAPLUS PUR 1645 Two-Component Polyurethane Potting Solution
Charging guns for new energy vehicles are constantly exposed to repeated plugging/unplugging, vibration, thermal cycling, outdoor humidity, rainwater, dust and electrical loads. For internal wiring harnesses, terminals, control circuits, connecting structures and cavity sealing positions of charging guns, potting compound is more than just a filling material — it is a core material that determines the product’s waterproofing, moisture resistance, electrical insulation, vibration resistance, weatherability and long-term reliability. Inside a charging gun lies a complicated cavity with dense wiring harnesses and tiny gaps between terminals and plastic housings. Potting compounds with excessively high fluidity tend to leak, overflow and cause contamination. Overly rigid cured resin, by contrast, may generate internal stress under low temperatures or long-term vibration from repeated plugging, undermining the structural stability of charging guns. Therefore, potting compounds for new energy vehicle charging guns must deliver a balanced set of properties: compatibility with narrow-gap structures, superior sealing performance, electrical insulation, waterproof & moisture resistance, low-temperature resistance, weatherability, flexible cushioning, and strong adhesion to both metallic and plastic substrates. ELAPLUS Functional Materials (Shanghai) Co., Ltd. has developed the two-component A/B polyurethane potting compound ELAPLUS PUR 1645, a reliable material engineered for cavity potting, wiring harness protection, terminal sealing and electronic component encapsulation of new energy vehicle charging guns. I. Why Do Charging Guns Require Specialized Potting Compounds? As frequently operated components within the EV charging system, charging guns are subject to combined stresses from mechanical plugging, ambient moisture, temperature fluctuations and strict electrical safety standards. Conventional potting materials rarely satisfy all requirements simultaneously, including sealing of complex cavities, controlled flow in narrow gaps, flexible stress relief and long-term protective stability. Specialized charging gun potting compounds are designed to resolve the following key challenges: ■ Cavity Sealing & Protection The intricate internal layout demands full filling of critical voids to block…
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