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Adhesive Solutions for PV Energy Storage Systems: Covering Structural Bonding, BMS/CCS Protection, Lithium Battery Potting, Thermal Management and PACK Sealing

2026-06-08

Against the backdrop of the dual carbon goals, grid integration of new energy and rapid expansion of power energy storage systems, PV energy storage systems are being upgraded toward higher power density, superior safety, longer service life and large-scale manufacturing. Whether for residential energy storage, commercial & industrial energy storage or large-scale energy storage power stations, battery packs, BMS, CCS busbars, thermal structures and sealing protection impose stricter requirements on adhesive materials. ELAPLUS Functional Materials (Shanghai) Co., Ltd. delivers systematic adhesive solutions for core applications including PV energy storage adhesives, energy storage battery potting compounds, BMS three-proof coatings, CCS UV adhesives, battery pack thermal conductive adhesives and pack sealants. Our solutions help customers improve the safety, reliability, weather resistance and production efficiency of energy storage systems. 1. Why Do PV Energy Storage Systems Require Professional Adhesives? PV energy storage equipment operates in harsh complex environments, enduring high-low temperature cycling, humidity & heat, dust, salt spray, vibration and impact, as well as heat accumulation and structural stress fluctuation during battery charge-discharge cycles. Improper adhesive selection may trigger bonding failure, degraded insulation, sealing leakage, insufficient thermal management and accelerated module aging. Therefore, adhesives in PV energy storage systems are far more than simple fixing materials. They undertake multiple functions: structural bonding, insulation protection, moisture & corrosion resistance, heat conduction & dissipation, shock absorption, waterproof sealing and lightweight design. Tailored to operating conditions of different positions in energy storage battery systems, ELAPLUS has built a full adhesive product matrix ranging from battery structural bonding to pack sealing. 2. Battery Structural Bonding: PUR 1610AB Balances Strength & Flexible Cushioning Reliable bonding is required between cells, structural components, brackets and housings of energy storage battery modules, while accommodating minor deformation and vibration impact during operation. Recommended Product: PUR 1610AB Polyurethane Structural Adhesive PUR 1610AB is…

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How to Choose Inductor Potting Compound?Elaplus EP 1712 Two-Component Epoxy Potting Compound Solution

2026-06-02

Inductors in power modules, automotive electronics, industrial control equipment, transformers, reactors, and inductor coils operate long-term under heat, vibration, moisture, voltage stress, and space-constrained conditions. For inductor products, potting compound is more than just a filler—it provides insulation, thermal conduction, moisture & shock resistance, flame retardancy, and structural fixation. Improper selection of inductor potting compound may lead to: ■ Adhesive cracking ■ Coil loosening ■ Reduced insulation ■ Excessive local temperature rise ■ Moisture intrusion ■ Debonding after vibration ■ Insufficient flame retardancy ■ Degraded long-term reliability For potting inductors, reactors, electronic coils, and high-reliability electronic modules, Elaplus EP 1712 two-component epoxy potting compound is recommended. EP 1712 features high hardness, good toughness, low volume shrinkage, UL94 V-0 flame retardancy, excellent electrical insulation, and strong moisture & shock resistance, ideal for inductor potting requiring high structural strength, insulation reliability, and long-term protection. 1. Why Do Inductors Need Potting Compound? Inductors consist of magnetic cores, copper windings, bobbins, pins, and housings. During operation, they are affected by current changes, magnetic fields, and environmental variations. Key functions of inductor potting compound: ① Insulation Protection Stable electrical insulation is required between coils, pins, solder joints, and magnetic cores. EP 1712 offers excellent electrical insulation after curing: Dielectric strength: 20 kV/mm (25°C) Volume resistivity: 2.00×10¹⁴ Ω·cm It reduces risks of leakage, breakdown, and short circuits. ② Thermal Conduction & Heat Dissipation Inductors generate heat during operation, especially in high-frequency power supplies, reactors, and power modules. Potting compound fills internal gaps to conduct heat from windings and cores to the housing or surrounding structures, reducing hotspots. ③ Moisture & Shock Resistance Long-term moisture exposure causes insulation degradation, terminal corrosion, and coil failure. EP 1712 forms a stable protective layer, blocking moisture, dust, and contaminants. It secures coils and lowers loosening risk from vibration. ④ Flame Retardant Protection Flame retardancy is critical in power,…

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How to Choose Sensor Potting Compound, Motor Potting Compound, and Power Supply Potting Compound? Elaplus Functional Materials Provides Reliable Solutions for Electronics, Automotive, and New Energy Equipment

2026-06-02

Electronic potting compound is simply a liquid polymer material poured into electronic components or between the housing and components. After curing, it forms an elastic or rigid protective layer that provides waterproofing, moisture-proofing, shockproofing, insulation, and thermal conductivity protection for circuit boards, modules, and components. It is one of the most widely used and technically demanding categories in the electronic adhesive family. The core mission of potting compound is not to bond, but to protect. When a power module is fully encapsulated with potting compound, moisture is blocked, vibration is dampened, and heat is efficiently dissipated—turning a fragile bare electronic device into a highly reliable unit with multiple times the designed service life. Currently, mainstream electronic potting compounds on the market fall into three chemical systems: silicone potting compound, epoxy potting compound, and polyurethane potting compound. ■ Silicone systems feature excellent high and low temperature resistance (−60°C to 260°C), low stress, and repairability, making them dominant in high-end applications such as new energy vehicles and photovoltaic inverters. ■ Epoxy systems excel in high strength and strong adhesion, suitable for scenarios requiring strict structural strength. ■ Polyurethane systems offer outstanding flexibility and low cost, widely used in home appliances and general industrial fields. Why Is Electronic Potting Compound So Important? The global electronic potting and encapsulation market is experiencing rapid growth. According to industry research, the global potting resin market reached $4.68 billion in 2025, and the flame-retardant electronic potting compound segment is projected to exceed $5.2 billion by 2032. As the world’s largest electronics manufacturing base and new energy vehicle market, China contributes the largest incremental share. The explosive demand for potting compounds is driven by three irreversible industry trends: ■ Electronic architecture revolution in new energy vehicles An electric vehicle uses 3–5 times more electronic components than a traditional fuel vehicle. Battery packs,…

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How to Select Potting Adhesives for Parking Radars?ELAPLUS — Sealing & Protection Solutions for Automotive Sensors

2026-06-01

Potting adhesives are critical to ensure long-term reliable operation of automotive ultrasonic parking sensors under extreme temperature & humidity, continuous vibration and high-pressure water spray. From the perspective of automotive electronics engineers, this article compares two mainstream solutions: silicone potting compounds and polyurethane potting compounds. It covers mixing ratios of two-component potting adhesives, low-temperature performance and waterproof potting processes for sensors. Meanwhile, we recommend two rigorously validated potting solutions from ELAPLUS for automotive sensors. When you shift into reverse, the dashboard lights up and the familiar beeping sound goes off — this is how a parking radar system works in daily use. Yet few people know what harsh conditions the ultrasonic sensors hidden inside the rear bumper have to endure: frigid temperatures as low as -40°C in winter in Northeast China, temperatures approaching 100°C after direct sunlight exposure in summer, direct impact from high-pressure water guns during car washing, weeks of high humidity in rainy seasons, plus constant vibration caused by countless starts and stops every day. A parking radar normally stays in service for over a decade, and its invisible yet essential protective layer is the potting adhesive. Industry research shows that the global parking radar market exceeded 60 billion RMB in 2026. With the widespread adoption of L2+ autonomous driving, ultrasonic radars are installed in more vehicles with higher reliability requirements. For sensor manufacturers, the selection of potting adhesives directly affects product aging resistance and end-user reputation. Choosing the right potting material for automotive electronics helps reduce after-sales failure rates and extend product service life. Based on real demands from automotive electronics engineers, ELAPLUS presents two fully qualified potting solutions for parking sensors. Potting Adhesive Selection for Parking Radars: Strict Performance Requirements for Sensors Before introducing specific products, let’s review the core criteria for selecting potting adhesives for…

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ELAPLUS SIPA 1850 High Thermal Conductivity & Anti-Poisoning Silicone Potting Compound – Recommended for LED Power Supplies

2026-05-28

In LED lighting, power adapters, outdoor lamps, industrial lighting, street light modules, landscape lighting and new energy electronic devices, LED drivers are core components that determine the overall stability and service life of luminaires. During long-term operation, LED drivers generate continuous heat. They are also exposed to moisture, dust, thermal cycling, vibration, impact and outdoor aging. Without adequate internal protection, risks such as overheated components, degraded insulation, failed solder joints, water ingress and short circuits, as well as compound cracking may occur. Therefore, selecting proper potting compound has become critical to improving the reliability of LED drivers. For LED driver potting applications, ELAPLUS recommends SIPA 1850 Two-Component Silicone Potting Compound. Featuring high thermal conductivity, high viscosity with thixotropy and excellent anti-poisoning performance, this product offers thermal conductivity ranging from 0.7 to 4.0 W/m·K, catering to heat dissipation requirements of LED power supplies with different power ratings. 1. Why Do LED Drivers Need Potting? An LED driver consists of capacitors, inductors, transformers, MOSFETs, rectifier bridges, IC chips, resistors, terminals and PCB circuits. Power components generate constant heat during operation, and accumulated heat will shorten the service life of electronic parts. Main functions of LED driver potting compound: ■ Heat Conduction & Dissipation: Transfer heat from power components to enclosures or heat dissipation structures. ■ Water & Moisture Resistance: Prevent moisture ingress and reduce risks of short circuit and corrosion. ■ Electrical Insulation: Protect PCBs and components for enhanced operational safety. ■ Vibration Damping: Mitigate impact from vibration during transportation, installation and use. ■ Dustproof & Sealing: Ideal for outdoor lamps, street lights and industrial lighting fixtures. ■ Service Life Extension: Improve long-term operational reliability of LED drivers. For outdoor LED power supplies, street light drivers, industrial light power units, landscape light power supplies and high-power LED driver modules, the potting compound shall not only achieve full filling,…

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Potting Adhesive Selection for Humanoid Robot Joint Motors: ELAPLUS Helps Frameless Torque Motors Break Heat Dissipation Bottlenecks

2026-05-27

With the advancement of AI technology, motion control algorithms and high-power-density motor technology, humanoid robots are evolving from conceptual designs into mass-produced products. Every joint, including robotic arms, knees, hips, ankles and dexterous hands, relies on motor systems featuring fast response, high torque and high precision. Frameless torque motors have become the core choice for driving humanoid robot joints. Featuring compact structure, light weight and high torque density, they can be directly integrated into robot joints, perfectly catering to the design requirements of miniaturization, lightweight design and high dynamic response for humanoid robots. As documented, frameless torque motors deliver fast response, low friction and high efficiency, well suited for joint drive applications of humanoid robots. However, challenges arise alongside these advantages: The smaller and more powerful a motor is, the harder it is to dissipate heat. For robot joint motors, frameless torque motors and servo motor stators, potting adhesives serve not only as protective materials, but also as key functional components for motor thermal management. ELAPLUS motor potting adhesives are specially formulated for humanoid robot motors. They deliver outstanding performance in thermal conduction and heat dissipation, electrical insulation, winding fixation, vibration resistance and long-term operational reliability for robot joint motors. 1. Why Do Humanoid Robots Adopt Frameless Torque Motors? A frameless torque motor is a frameless permanent magnet brushless synchronous motor, mainly composed of a rotor and a stator. The rotor is a rotating steel ring embedded with permanent magnets and can be directly mounted on the machine shaft. The stator consists of laminated silicon steel sheets and copper windings that generate electromagnetic force and are integrated inside the housing. Compared with conventional motors, frameless torque motors offer distinct advantages for humanoid robots: ■ High torque density: Delivers higher torque output within the limited space of robot joints. ■ Low inertia: Enables…

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How to Select Potting Compounds for Motors, Connectors and Temperature Sensors? ELAPLUS EP 1796 Heat-Curable Epoxy Potting Compound Solution

2026-05-26

For applications including motor stators, connectors, temperature sensors, pressure sensors, power modules, industrial control modules and reactors, potting compounds not only serve as filling and protection materials, but also directly determine electrical insulation reliability, high-low temperature resistance stability, crack resistance and long-term service life of finished products. Especially in scenarios with severe high-low temperature cycling, long-term high-temperature exposure, strict electrical insulation requirements and high dimensional stability, conventional potting materials tend to suffer from cracking, shrinkage, debonding, insulation degradation and bubble residue. To meet such high-reliability potting demands, ELAPLUS recommends EP 1796 A/B heat-curable potting compound. It is a two-component solvent-free heat-curable epoxy potting material featuring excellent processability and adjustable mixing ratio. With superior high-low temperature aging resistance, it is suitable for potting reactors, connectors, pressure sensors, temperature sensors, industrial control modules and motor stators. I. Why High–Reliability Potting Compounds Are Required for These Applications 1. Motor Stator Potting: Simultaneous Exposure to High Temperature, Vibration and Thermal Stress Motor stators continuously generate heat during operation, while windings, iron cores and housings feature different thermal expansion behaviors. Excessively high linear thermal expansion coefficient or large curing shrinkage of potting compounds may cause cracking, coil loosening and insulation degradation. Therefore, motor potting compounds shall have: ■ High-low temperature shock resistance ■ Low linear thermal expansion coefficient ■ Excellent electrical insulation ■ High hardness and good toughness ■ Long-term heat resistance EP 1796 features low linear thermal expansion coefficient, low curing shrinkage, high hardness and good toughness, making it ideal for potting protection of motor stators, coils and high-temperature electrical structures. 2. Connector Potting: Insulation, Moisture Resistance and Dimensional Stability Are Critical Connectors operate under continuous electrical connection, with internal pins, terminals, solder joints and wire harness joints requiring strict insulation and sealing. Large shrinkage of potting compounds may cause stress concentration around terminals; insufficient temperature resistance may lead…

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How to Select Motor Potting Compound?EP 1716 High-Thermal-Conductivity Epoxy Potting Compound Delivers One-Stop Thermal Dissipation & Reliability for Motors

2026-05-26

A palm-sized stator winding carries hundreds of amperes of electric current; a drive motor generates continuous heat at rotational speeds of tens of thousands of revolutions per minute. Potting compound serves as the final safeguard securing motor operational safety. If motors are the “hearts” of new-energy vehicles and industrial automation, motor potting compounds are the “pericardia” protecting these hearts. They must deliver efficient heat conduction and dissipation, reliable electrical insulation, and resistance to extreme temperature shocks ranging from -50°C to 180°C. Should the wrong compound be chosen for this triple-mission task, the consequence could be full-product recalls. Cutting straight to the point, today we introduce ELAPLUS EP 1716, a high-thermal-conductivity epoxy potting compound that excels specifically in motor stator potting applications. We back our claims with solid performance parameters. I. Why Is Motor Potting Becoming Increasingly Demanding? Latest data shows the global potting compound market reached approximately USD 3.9 billion in 2025, among which automotive thermal‑conductive potting compounds alone exceeded USD 1.2 billion, projected to surge to USD 2.5 billion by 2034. This growth is primarily driven by the booming new-energy vehicle, industrial servo motor and 5G electronic packaging sectors. Take new-energy vehicles as an example. The power density of mainstream drive motors has risen from the early 2-3 kW/kg to 5-7 kW/kg or higher today. Doubled power density means nearly doubled heat generation per unit volume of windings. Meanwhile, the rapid rollout of 800 V high-voltage platforms has raised requirements for motor insulation systems from “basic sufficiency” to “absolute reliability”. In traditional processes, motor stator windings are fixed and protected mainly by impregnating varnish. Yet such varnishes typically feature a thermal conductivity of only 0.2–0.3 W/m·K with insufficient filling capacity, leaving massive air gaps between coils and iron cores. Air, with a thermal conductivity of merely 0.026 W/m·K, acts as a natural thermal barrier….

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How to Select Potting Compounds for Automotive Controllers?ELAPLUS SIPA 1850 High-Thermal-Conductivity & Flame-Retardant Potting Solution

2026-05-25

I. Why Do Automotive Controllers Require Potting? Automotive controllers generally consist of PCBs, capacitors, inductors, chips, connectors, power devices, sensing units and other components. They are widely applied in electronic modules including: motor controllers, body controllers, water pump controllers, battery management system (BMS) control modules, thermal management controllers, fan controllers, etc. During operation, these modules are exposed to multiple environmental factors: ■  Continuous heat generation from high‑power devices ■  Vibration and impact caused by vehicle movement ■  Intrusion of moisture, water vapor and dust ■  Material stress changes induced by thermal cycling ■  Insulation risks under high‑voltage electrical conditions ■  Complex internal controller structures with limited heat-dissipation space Without reliable potting protection, controllers may suffer performance degradation or even failure during long-term operation. Core functions of potting automotive controllers include: ■  Thermal conduction and heat dissipation ■  Electrical insulation protection ■  Moisture-proof and waterproof performance ■  Anti-vibration and shock buffering ■  Fixation of electronic components ■  Improved flame-retardant safety ■  Reduced thermal and structural stress impacts ■  Enhanced long-term reliability of controllers II. Challenges in Selecting Potting Compounds for Automotive Controllers Not all potting compounds that can be poured into modules are suitable for automotive electronics. Controllers in particular demand comprehensive high-performance materials. Power devices, inductors, capacitors, chips and other components inside controllers generate heat during operation. Insufficient thermal conductivity of potting materials traps heat, leading to excessive local temperature rise and shortened service life of electronic components. Therefore, potting compounds for automotive controllers must feature excellent thermal conductivity. Controllers have complex internal structures with numerous gaps and dead zones between components. Poor flowability of potting compounds causes incomplete filling, residual bubbles and voids under components. Well-flowing potting compounds penetrate component gaps better, improving encapsulation integrity and consistency. Excessive shrinkage during curing exerts stress on components, solder joints and PCBs, even causing solder joint cracking, component deformation or bonding interface failure. Low curing shrinkage reduces…

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