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Case study of photovoltaic energy storage cell bonding: High performance application of PUR 1655 multifunctional polyurethane adhesive

2025-08-07

With the large-scale application of photovoltaic and energy storage systems, the bonding and fixing process of battery cells as the core of energy storage battery systems is increasingly valued by the industry. Especially in the integration process of large battery modules, it is not only required that the adhesive has high-strength adhesion, but also multiple performance indicators such as waterproof, dustproof, anti-aging, and environmental protection should be taken into account. In practical applications, many conventional sealants face problems such as poor coating adaptability, narrow bonding range, strong odor, and inconvenient construction, which seriously affect the reliability and manufacturing efficiency of energy storage systems. Adhesive bonding of photovoltaic energy storage cells To address the above challenges, this article will share the application case of ELAPLUS multifunctional polyurethane sheet metal sealant PUR 1655 in the “photovoltaic energy storage cell bonding and fixation” project, analyze its outstanding performance in complex environments, and provide reliable material solutions for new energy enterprises.1、 Project background: Challenges faced by battery cell bondingIn an energy storage system, the arrangement of battery cells is usually a regular parallel or stacked layout, which is then packaged into battery modules. The entire module needs to go through the following operational challenges:High requirements for structural bonding strength: During transportation and use, battery cells need to withstand vibration and thermal shock. Colloids must have high modulus and bonding strength to avoid loosening and detachment.High long-term aging resistance requirements: Photovoltaic energy storage systems typically have a service life of over 10 years, and outdoor installations require colloids to not age or crack in environments such as ultraviolet radiation, humidity, rain, and snow.High requirements for process friendliness: When producing in large quantities, it is required that the colloid is easy to operate, easy to apply, free of primer, fast to apply, and compatible with coating…

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Case Study of Sealing Automotive Air Conditioning Temperature Sensors: EP 1710 Epoxy Sealing Adhesive Solution for High Waterproof Performance

2025-08-07

With the continuous improvement of automotive intelligence, comfort, and durability requirements, the stable operation of onboard sensors has become a key link in ensuring the performance of the entire vehicle. Among them, the automotive air conditioning temperature sensor, as the core component for regulating cabin temperature, has a direct impact on the response speed and comfort experience of the in car air conditioning system in terms of accuracy and reliability. However, in long-term use, sensors often face a serious challenge – condensation water seeps in, causing internal thermistor failure. How to provide long-term and reliable waterproof protection for temperature sensors has become an important issue in the design of automotive electronic materials. 1、 Project background: Performance challenges under condensed water erosionDuring the operation of the car air conditioning system, especially in humid or high temperature environments, condensation water is easily generated on the sensor surface. These water droplets may seep into the interior along the leads or seams, and once they enter the poorly sealed sealing area, they will reach the thermistor area, causing deterioration or even complete failure of electrical performance.Traditional sealing materials often perform poorly in the face of this “boiling water” environment. High temperature and high humidity conditions can accelerate the aging of colloids, leading to decreased insulation performance, lower breakdown voltage, and water absorption expansion. To this end, the vehicle manufacturer has added a rigorous testing project -1000 hours of 85 ° C water boiling test, and determines whether the material is qualified by comparing the changes in insulation resistance and withstand voltage performance before and after the test. 2、 Analysis of adhesive requirements: not only waterproof, but also durableAccording to the testing standards and application scenario requirements proposed by the customer, the sealing adhesive for automotive air conditioning temperature sensors needs to meet the following…

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Robot Joint Motor Sealing Solution | EP 1720 Flexible Epoxy Adhesive Performance Explanation

2025-08-05

With the rapid development of AI, industrial automation, and intelligent manufacturing, robots have penetrated into every corner of our lives and industriesFour legged robots run on inspection sites, collaborative robotic arms precisely assemble mobile phone chips, exoskeleton equipment helps rehabilitation patients walk again These seemingly futuristic scenes have become realityWith the continuous evolution of robots towards lightweight, high-precision, and intelligent collaboration, joint motors, as the “driving core”, are facing multiple challenges in power density, heat dissipation, and reliability. Material breakthroughs have become the key to improving its performance.Frameless torque motor – the central power of efficient robot systemsFrameless Torque Motor is designed specifically for high-performance robots and industrial automation. With its advantages of compact structure, light weight, and strong output, it is gradually replacing the traditional combination of “reducer+servo motor” and becoming the new generation of power core.The electromagnetic system has been optimized and designed to increase torque and power density by up to 25%, meeting the urgent demand for high-efficiency output in lightweight systems. Internally integrated Hall and temperature sensors, combined with advanced encapsulation technology, ensure excellent heat resistance and long-term stability even in high temperature environments, while achieving precise control and real-time monitoring. Behind the technical difficulties lies the material bottleneckElectromagnetic efficiency is no longer the only pursuit, “structure+thermal management+reliability” is the new generation competitiveness of robot joint motors.Soft magnetic materials under high power are prone to saturation and suffer from significant eddy current losses;The thermal expansion stress caused by extreme temperature differences affects the lifespan of electronic components;Difficulty in heat dissipation under a closed shell and the threat of moisture intrusion to system safety;The cogging torque causes low-speed shaking, which affects the cooperation accuracy;Under long-term operation, bonding/sealing materials are prone to aging and cracking.EP 1720- Creating a Robot Core Power Safety Barrier To cope with the extreme…

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Displacement Sensor Encapsulation Solution | EP 1710 for High Temperature, Low Stress, and High Adhesive Packaging Applications

2025-08-05

In the fields of industrial automation and precision measurement, displacement sensors are widely used as core sensing components in high-precision control systems such as mechanical equipment, automotive manufacturing, aerospace, etc. To ensure its stable operation in complex environments, encapsulation protection has become an indispensable process step. This article will take the practical application of a displacement sensor manufacturer as an example to share how to successfully achieve transparent, low stress, high adhesion, high temperature resistance, moisture and waterproof packaging effects by using EP 1710 two-component epoxy sealant. Sealing of distance sensorIndustry pain point: Failure risk of displacement sensors under extreme working conditionsIn scenarios such as automotive engine compartments and industrial automation equipment, displacement sensors have long faced three major challenges:High temperature deformation: 150 ℃+environment causes colloidal expansion, squeezing sensitive components and causing signal drift;Metal interface cracking: Colloids and shells peel off during cold and hot cycles, and moisture invades and damages the circuit;Internal stress damage: Curing shrinkage stress reduces the displacement accuracy of micrometer level sensing elements. Solution: EP 1710A/B high-performance epoxy sealant A new energy vehicle component manufacturer has achieved a key performance breakthrough in the turbocharger displacement sensor project by replacing traditional silicone with EP 1710Core application effectPerformance Requirement EP 1710 SolutionHigh temperature stability at 150 ℃, thermal deformation temperature>180 ℃, CTE at 150 ℃ is only 28ppm/℃ (lower than the metal shell), zero expansion at high temperature;Metal bonding strength: Aluminum alloy bonding strength ≥ 12MPa, passing through -40 ℃ ↔ 500 cycles of cold and hot shock at 150 ℃ without delamination;Waterproof and moisture-proof, with a water absorption rate of less than 0.05%, achieving IP68 protection level after curing, and maintaining insulation resistance of more than 10 ¹⁵ Ω in humid and hot environments (85 ℃/85% RH);Transparent low stress transmittance>90%, curing shrinkage<0.2%, effectively protecting the structure of…

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MINI LED dam adhesive application case sharing: Choosing the right adhesive, the key is “matte+thixotropic”

2025-08-05

In the field of MINI LED display packaging, the enclosure process has put forward higher requirements for the adhesive properties:Not only must it have precise molding and controllable flow, but it must also have a matte effect to suppress diffuse reflection, avoid light pollution, and improve overall display quality. LED dam sealant Customer requirementsNeed matte finish to reduce diffuse reflectionPaste with good operabilityGood adhesion and reliabilitySolution: ELAPLUS EP 1761We recommend Elaplus’s independently developed EP 1761 black single component epoxy dam sealant, which is specifically designed for high-precision electronic packaging and has the following key advantages:✅ Matte black appearance: effectively absorbs excess light and avoids diffuse reflection interference✅ Low viscosity+strong thixotropy: with good thixotropy, smooth and non collapsing edges, and regular dam forming✅ Fast and efficient thermal curing: can achieve rapid curing according to process settings, improving production pace✅ Excellent mechanical strength and electrical performance: impact resistance, vibration resistance, and reliable insulation after bonding, ensuring long-term stable operation✅ Compatible with multiple substrates: can provide high-strength adhesion to common materials such as glass, metal, ceramics, etc✅ Excellent resistance to moisture and aging: adaptable to harsh application environments, enhancing the lifespan of end productsTypical application scenarios:MINI LED&Micro LED display fencePrecision optical component packagingCamera module light shielding packagingAutomotive sensors, connectors, and magnetic sheet bondingSummary:In today’s increasingly sophisticated high-end display technology, using the right adhesive is a crucial step in determining quality. Elaplus EP 1761, with its matte appearance, excellent thixotropy, and high reliability, is becoming the preferred adhesive solution for many LED customers in dam enclosure processes.Tags: LED · LED dam sealant · Epoxy adhesive

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MEMS chip packaging material upgrade: new trend of FSGEL 3200 sensor potting adhesive

2025-08-05

In today’s rapidly developing microelectronics technology, MEMS (Micro Electro Mechanical Systems) chips play a crucial role in high-precision fields such as automotive, medical, and industrial control. Due to its precise internal structure and small size, higher requirements are placed on the encapsulation material – not only to provide excellent electrical insulation performance, but also to have excellent flexibility and resistance to environmental stress. MEMS chip packaging At present, commonly used materials in the market, such as 927F from a certain brand, although widely used in the early days, have gradually revealed limitations such as high oil separation, narrow process window, and high price. Therefore, the customer hopes to find a solution that is equivalent in performance, more stable in process, and can completely replace 927F/Recommended product solutionsThe newly launched FSGEL 3200 by ELAPLUS is a one component fluorosilicon gel specially designed for MEMS, sensors and other precision electronic devices, which can stably replace the 927F and achieve dual upgrading in process and performance:MEMS chipPerformance Highlights Excellent flexibility, forming buffer gel after curing, absorbing stress and protecting chip structureWide range of high and low temperature resistance: -60 ℃ to 250 ℃, suitable for harsh working conditionsExcellent electrical insulation performance: dielectric strength of 25 kV/mm, volume resistance of 10 ¹⁵Ω· cmNo oil separation after curing, improving packaging stabilitySingle component design, more efficient dispensing, supports automationResistant to chemical corrosion and moisture erosion, enhancing long-term reliabilityTypical applicationsSuitable for sealing products such as automotive exhaust sensors, urea sensors, fuel tank temperature sensors, connectors, precision MEMS components, etc.In practical verification, FSGEL 3200 performs well, with uniform curing, transparent and bubble free properties, and no performance decline after long-term aging. It can completely replace 927F for mass production.Every packaging substitution is a reconstruction of trust in materials and processes. FSGEL 3200 is not just a substitute, it…

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Solution for adhesive fixation of car buzzers: Stainless steel and plastic are firmly combined, choosing SIPC 1859 is definitely the right choice!

2025-08-01

In automotive electronic components, the buzzer plays an important role as a sound alarm device, providing safety reminders. It works stably in harsh environments such as high temperature, high humidity, and vibration, which places extremely high demands on structural adhesive bonding. Especially the bonding between the stainless steel shell and the plastic base should not only be firm and reliable, but also take into account long-term aging and environmental resistance.Application difficulty: Challenges in bonding stainless steel and plasticThere are significant differences in materials and thermal expansion coefficients, which can easily lead to stress cracking due to temperature changes;Continuous high temperatures or exposure to sunlight can accelerate the aging of colloids;There are multiple interferences such as oil pollution, moisture, and vibration in the working environment;The installation space is narrow, requiring easy operation and quick positioning of the adhesive. In automotive electronic components, the buzzer plays an important role as a sound alarm device, providing safety reminders. It works stably in harsh environments such as high temperature, high humidity, and vibration, which places extremely high demands on structural adhesive bonding. Especially the bonding between the stainless steel shell and the plastic base should not only be firm and reliable, but also take into account long-term aging and environmental resistance. Application difficulty: Challenges in bonding stainless steel and plasticThere are significant differences in materials and thermal expansion coefficients, which can easily lead to stress cracking due to temperature changes;Continuous high temperatures or exposure to sunlight can accelerate the aging of colloids;There are multiple interferences such as oil pollution, moisture, and vibration in the working environment;The installation space is narrow, requiring easy operation and quick positioning of the adhesive. ✅ Recommended product: Elaplus SIPC 1859 silicone adhesive sealantSIPC 1859 is a dealcoholized RTV room temperature vulcanized silicone gel designed specifically for bonding different materials…

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New cable sealing solution: PUR 1680, creating a reliable waterproof barrier!

2025-08-01

In high-end equipment such as modern industry, communication, and new energy, cable sealing issues are receiving increasing attention. Whether it is waterproof sealing for outdoor use of equipment or long-term sealing protection for cable outlets inside control systems, a material that is both flexible, long-lasting waterproof, and has good adhesion is needed.In response to this demand, ELAPLUS has launched PUR 1680 two-component polyurethane sealant, designed specifically for waterproofing cable outlets and sealing equipment interfaces, combining environmental friendliness, reliability, and multi material adaptability. Cable waterproof sealing1、 Application pain point analysis: challenges of traditional sealing methodsIn practical cable sealing applications, traditional sealing materials such as silicone rubber rings, heat shrink tubing, or ordinary epoxy adhesives often face the following problems:Incomplete sealing: The gaps cannot be completely filled, making it easy for water to seep through.High water absorption rate: After colloid solidification, the water absorption rate is high, leading to a decrease in performance.Easy to age and harden: When used outdoors, it is easily affected by ultraviolet rays, rain and snow, and rapidly ages.Poor adhesion: The adhesion with plastic, cable sheath or metal shell is not firm, and it is easy to fall off or bulge after a long time.Difficult to cure deeply: Complex structures often cannot be fully cured due to air blockage or poor colloidal fluidity.These issues can pose great risks to the stable operation of equipment, especially in humid, high-temperature, or salt spray corrosive environments, where performance may decrease at the slightest, and in severe cases, short circuits or system failures may occur.2、 Recommended product: PUR 1680- Professional cable sealing material Cable sealing material Product IntroductionPUR 1680 A/B is a two-component, solvent-free polyurethane elastomer sealing and potting material with excellent mechanical, sealing, and adhesive properties. It can be used for room temperature or heat curing to meet different process requirements.Mixing…

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ELAPLUS Case Study: Application of EP 2012 Epoxy Adhesive in Automotive Electronic Wire Speed Fixation

2025-07-29

With the continuous development of automotive electronic technology, more and more complex electronic systems are integrated into vehicles, especially electric vehicles and autonomous vehicle. These systems have extremely strict requirements for the protection of electronic components. In these applications, the fixation and protection of solder joints and circuits are crucial, especially in extreme temperatures and harsh environments. In order to meet these demands, EP 2012 two-component epoxy structural adhesive has become the preferred material for many automotive electronics manufacturers due to its excellent high temperature resistance, adhesive strength, and protective performance for automotive electronic components. Customer needs and challengesThe client in this case is a leading automotive electronic system supplier, specializing in the development of electric vehicles and autonomous driving technology. The customer’s needs mainly focus on the following aspects:Solder joint fixation and protection: With the increasing demand for electronic components in automotive electronic systems, especially the complex connections between battery management systems (BMS) and autonomous driving sensors, the stability of solder joints is crucial.High and low temperature resistance: Automotive electronic products must operate reliably in extreme environments, especially in temperature fluctuations ranging from -40 ℃ to 150 ℃.Milk white appearance: Due to the long-term use of the product in the car system, it is required that the gel has a milk white appearance in order to efficiently repair and maintain it without affecting the overall visual effect.Flame retardant performance: In automotive electronics, safety is particularly important, especially in situations such as collisions or battery failures, where flame retardancy is indispensable.Solution for EP 2012 two-component epoxy structural adhesiveTo meet the customer’s requirements, we recommend EP 2012 two-component epoxy structural adhesive. This product is a room temperature/heating cured resin adhesive, particularly suitable for bonding materials such as metals, ceramics, fiberglass, etc., and can work stably in the extreme temperature range of…

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