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Elaplus Solution for Encapsulation of Industrial Sensor Probe Wiring Harness

2024-12-26

BackgroundWith the widespread application of industrial automation and intelligent devices, the role of sensor probes and wiring harnesses in various electronic devices has become increasingly important. Especially in the fields of automotive electronics, smart homes, industrial control, and communication equipment, the reliability of sensors and wiring harnesses directly affects the performance and lifespan of the equipment. Therefore, ensuring the stability of these electronic components in harsh environments such as high temperature and humidity has become a major challenge in design and production.In this regard, encapsulation technology, as an effective protective measure, has been widely used in the manufacturing of industrial sensors. As a leading provider of high-performance polyurethane materials, Yilian Electronic Adhesive provides efficient solutions for the encapsulation needs of sensor probe harnesses. This case study will provide a detailed introduction to the performance and advantages of Yilian PUR 1670 series polyurethane potting adhesive in the application of sensor probe wire harness potting. Customer DemandElaplus’s customers face a series of stringent performance requirements when producing industrial sensor probe harnesses, mainly including:▶ Good adhesion performance: The sealing material is required to have strong adhesion to commonly used substrates such as polyvinyl chloride (PVC) to ensure the firmness and durability of the sensor probe harness.▶ High temperature and low impact performance: In the working environment of sensors, temperature changes are extremely severe, especially in fields such as automobiles and power equipment. It is required that the sealing material can withstand a temperature difference of -40 ℃ to 85 ℃, and there will be no cracks or damage within this temperature range.▶ High bonding strength: Customers have high requirements for the bonding strength of the potting adhesive, especially requiring a bonding strength of at least 8.9 kilograms to ensure the long-term stability of the sensor probe harness.SolutionIn response to customer needs, Elaplus recommends…

Elaplus Case Study on Fixing Wiring Harness of Electric Tool Control Board

2024-12-25

In the electric tool industry, the fixing and bonding of control board wiring harnesses are important links to ensure equipment stability and safety. The wire harness needs to withstand severe tests such as long-term vibration, mechanical impact, and environmental temperature and humidity changes, so choosing the appropriate adhesive is particularly crucial. Elaplus provided customers with PUR 1603 two-component solvent-free adhesive, helping them solve multiple challenges in fixing control board wiring harnesses. This article will share in detail this case, analyzing customer needs and how Elaplus provides ideal solutions for customers through PUR 1603. Case background: Fixed requirements for wire harness of power tool control boardThe client is a well-known power tool manufacturer specializing in the development of high-performance power tools and their accessories. The control board wiring harness typically needs to withstand complex working environments inside electric tools, including high-frequency vibrations, temperature fluctuations, and exposure to chemicals. Therefore, the customer has put forward the following key requirements for the adhesive fixation of the control board harness:After curing, the hardness is high, ranging from 50-70D: Due to the significant mechanical impact experienced by electric tools during operation, customers require the adhesive to be cured to achieve sufficient hardness and provide sufficient support to ensure that the wiring harness is not loose.Good adhesion performance of silicone wire: Silicone wire is often used as an insulation material for cables in electric tools, so when bonding silicone wire, the adhesive needs to have good adhesion.Room temperature curing: The customer hopes that the adhesive can be cured at room temperature to simplify the production process and improve production efficiency.Solution: PUR 1603 two-component adhesivePUR 1603 A/B is a two-component solvent-free room temperature curing adhesive. Low odor, low VOC, compliant with ROHS and REACH regulations. Wide process operability, high physical properties of finished products, suitable for machine…

Elaplus Customer Case Study: Adhesive Bonding of Sensor Wiring Harness

2024-12-25

In the fields of automotive electronics and industrial sensors, the fixation and bonding of wiring harnesses and sensors are crucial. With the increasing demand for reliability and durability of equipment, choosing the appropriate adhesive has become one of the key factors. Yilian has accumulated rich experience in this area, especially in providing efficient and durable bonding solutions for sensor wiring harnesses. This article will introduce in detail how Elaplus solves the needs of customers for strong adhesion and high durability through EP 1715 epoxy adhesive through a customer case study. Case background: Fixed requirements for sensor wiring harnessThe client is a leading industrial sensor manufacturer focused on developing sensor solutions for use in smart devices and automation systems. To ensure the stability and durability of the sensor, customers need to firmly bond the wiring harness to the sensor when designing their products. Due to the fact that these sensors are often used in harsh working environments such as high temperatures, high humidity, and electromagnetic interference, ensuring the strength and long-term stability of adhesive fixation is a crucial challenge.The customer has tried various adhesive materials in the early stages, but the challenge they face is that the adhesive strength of most adhesives is not sufficient to withstand long-term tension and environmental changes, resulting in loose or detached wiring harnesses during operation. At the same time, the customer requires the adhesive to have strong toughness after curing, to avoid brittle cracking under vibration or mechanical impact. In addition, the adhesive needs to have excellent moisture resistance, aging resistance, and good electrical performance.Challenges and SolutionsAfter multiple communications and tests, Yilian recommended EP 1715 epoxy adhesive to the customer. This two-component epoxy resin adhesive can meet the customer’s multiple needs for fixing sensor wiring harnesses. After testing, the customer’s requirements for fixing sensor wiring…

Industrial electronic control unit thermal potting solution: PUR 1680 high-performance potting adhesive application case sharing

2024-12-24

In modern industrial control systems, electronic control units (ECUs) are important components that ensure precise operation and safety of equipment. Especially in application scenarios that require high reliability, such as automobiles, robots, energy management, etc., ECU needs to operate continuously and stably under extreme environmental conditions. This not only places high demands on its functionality, but also poses severe challenges to its heat resistance, vibration resistance, and waterproofing. Therefore, choosing appropriate sealing materials can not only improve the reliability of ECU, but also effectively extend its service life. Background and ChallengesElectronic control units (ECUs) are typically installed in mechanical equipment or vehicles and are exposed to environmental conditions such as high temperatures, vibrations, moisture, and chemical corrosion for extended periods of time. For applications with high power current density, if the heat generated by the ECU cannot be effectively dissipated, it may cause component overheating, thereby affecting the performance of electronic components and even leading to malfunctions. Thermal management and mechanical protection have become important issues in design and application.Therefore, heat dissipation and management, especially thermal conductivity, have become key considerations when choosing sealing materials. In addition, the anti vibration and waterproof/dustproof properties must also meet industry standards to ensure the long-term stable operation of electronic control units in complex environments.Recommended product: PUR 1680 thermal conductive sealantPUR 1680 thermal conductive sealant is an ideal solution for addressing these challenges in industrial electronic control units. PUR 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 do not contain heavy metals, are environmentally friendly, have wide process operability, high physical properties of the finished product, and good adhesion to the substrate. It can be cured at room temperature or by heating, and can be deeply cured. The two-component…

Elaplus Case Study on wire fixing in speed differential pressure sensor

2024-12-24

In modern industrial and automotive electronic devices, the reliability and durability of sensors are crucial, especially differential pressure sensors, which require long-term stable operation in extreme environments. The fixed line speed of differential pressure sensors is an important aspect that cannot be ignored. It not only affects the performance of the sensor itself, but also is closely related to the overall stability and safety of the product. Today, we will introduce a product that provides an ideal solution for such applications – SIPC 1811 RTV silicone adhesive sealant. Background and Challenges: Application Requirements for Differential Pressure SensorsDifferential pressure sensors are widely used in important fields such as measuring liquid and gas flow rates, monitoring filtration systems, etc. These applications often require sensors to operate continuously and stably under extreme temperatures, moisture, vibrations, and chemical substances. To ensure the long-term reliability of the sensor, fixing the line speed is a very important step. This process involves applying appropriate adhesion and sealing on the outside of the sensor to ensure that its connection is not affected by the external environment, and to avoid faults caused by mechanical shock, thermal shock, or moisture erosion.However, fixed line speed faces a series of challenges, mainly including:Performance retention in high and low temperature environments: Sensors often operate between -60 ℃ and 260 ℃, and the fixing material must be able to adapt to these extreme temperature changes.Waterproof and moisture-proof: The erosion of moisture, dirt, and other atmospheric components is an important factor affecting the performance of sensors, especially in outdoor or humid environments.Long term mechanical and thermal shock: In vehicles or industrial equipment, sensors are often subjected to mechanical pressures such as vibration and impact, and fixing materials need to effectively reduce the stress and tension caused by these pressures.Electrical insulation and corona resistance: The electrical…

Challenge and Solution of Motor Stator Potting : EP 1788’s All-round Performance Support

2024-12-23

In the production of motors, automotive electronics and other high -performance equipment, the potting of stator is a crucial process. In order to ensure the stability and safety of the motor in various extreme environments, it is important to choose the appropriate sealing materials. Today, Elaplus will share a customer case about motor stator potting, telling how to successfully meet the customer’s high requirements by using the EP 1788 dual -component segmentation potting and potting glue, and solve multiple technical challenges. Customer demand backgroundWhen customers produce motor stator, they face the following key needs: The irrigation effect of black and non -bubbles: The appearance of the motor stator requires black, and the production of bubbles must be avoided during the seal to ensure the neatness of the appearance and the internal potting.Normal temperature curing: Customers hope to complete the sealing in normal temperature environment without relying on high -temperature curing equipment, which not only reduces costs, but also improves production efficiency.Lubricating oil: Considering that the motor may be exposed to lubricating oil during use, the irrigation and sealing must have excellent oil resistance to avoid the erosion of the lubricating oil on the seal layer.High and low temperature impact non-cracking: Customers require that the sealing glue can withstand high and low temperature shocks from -40 ° C to 150 ° C without cracking. The motor may face extreme temperature difference changes during operation, so temperature resistance and crack resistance are essential.Non -bubbles, good sealing: During the sealing process, the glue is required to have no bubbles to ensure that the internal seal is completely seal, so as to avoid potential problems caused by bubbles, such as poor electrical contact or structural weakness.Solution: EP 1788 dual -component segmentation oxygen pottingFor the specific needs of customers, we recommend using EP 1788 series…

Case Sharing:Explosion-proof switch potting : EP 1712+Sigel 1806 double protection

2024-12-23

Explosion -proof switches are widely used in high -risk industries such as petroleum, chemical industry, and electricity. In the face of high temperature, high humidity, vibration and other complex environments, they need to have excellent earthquake resistance, waterproof, and corrosion resistance to ensure the safety of the equipment. The explosion -proof and sealing technology is an effective means to protect the explosion -proof switch from being affected by external environment. Papering can not only provide additional mechanical protection, but also effectively prevent internal components from moisture and corrosion, avoid poor electrical contact and other problems, and ensure the stable work of explosion -proof switches in harsh environments. However, the sealing demand of explosion -proof switches is challenging, especially in the choice of glue’s liquidity, bottom sealing, and solidifying method. Explosion-proof switchchallengeWhen choosing an irrigation material for explosion -proof switches, the design team is facing the following challenges: Moderate liquidity of glue: The irrigation sealing needs to have good liquidity in order to penetrate into every corner of the switch and ensure that each contact point is fully covered. However, over -flowing glue can cause the glue to penetrate into a area where it should not be penetrated, which will affect the performance of the switch.The bottom sealing: The explosion -proof switch is often facing the risk of glue from the bottom during the sealing process, especially before solidification. Therefore, ensuring the sealing of the bottom is another key issue. If the bottom leakage is leak, it may cause incomplete seal effect and even affect the security of the switch.Normal temperature curing: In many industrial applications, explosion -proof switches may require irrigation operations without high temperature equipment. Therefore, it is particularly important to choose an irrigation and sealing that can be solidified at room temperature.Recommended product EP 1712A/B is a dual-component-free…

Elaplus Case Sharing of Waterproof Gel Box Potting: Application and Advantages of ELAPLUS SIGEL 1809

2024-12-20

In modern electronic products, waterproofing, insulation, and stress relief are key to ensuring long-term stability and reliability. Especially in fields involving underwater applications, optical cable splice boxes, and waterproof junction boxes, selecting suitable potting materials is particularly important. To meet these needs, Elaplus SIGEL 1809, as a two-component self-healing silicone gel, has become the choice of waterproof gel box filling solution with its excellent performance and various advantages.Waterproof gel box filling. Background and ChallengesWith the advancement of technology, the application of electronic products in various harsh environments is becoming increasingly widespread. Especially in underwater equipment, communication infrastructure, and power equipment, the importance of waterproofing and insulation performance is self-evident. Taking fiber optic splice boxes as an example, these devices are usually installed outdoors or underground and need to withstand extreme environmental challenges such as high humidity, temperature differences, and physical stress. Its main function is to connect and protect optical cables or cables, preventing external pollutants such as moisture and dust from infiltrating, which imposes strict requirements on the selection of materials.For traditional potting materials, although they can provide certain waterproof and insulation effects, they often lack long-term stability and weather resistance, especially under extreme weather conditions, which can lead to aging, cracking, or performance degradation. For the application of optical cable splice boxes and other equipment, it is also necessary to consider requirements such as stress relief and high-voltage electrical insulation. How to find a material that can ensure good waterproof effect, high temperature electrical insulation and stress relief performance has become an urgent problem for technical personnel in this field.The unique advantages of Elaplus SIGEL 1809Elaplus SIGEL 1809 is a transparent two-component self-healing silicone gel, which forms a special soft material with buffer and automatic recovery after curing. Used to isolate moisture and other harmful pollutants from contacting…

Elaplus Case Study on PCB Protection and Encapsulation of Bluetooth Sensor for Automobile Electric Tailgate

2024-12-19

With the rapid development of automobile intelligence and electrification, electric tailgate has become one of the indispensable functional components in modern cars. As the core part of this system, the Bluetooth sensor PCB not only requires precise signal processing and connection functions, but also must be able to withstand harsh conditions in the automotive environment, including high temperature, humidity, vibration, salt spray and other complex environments. Therefore, the requirements for its protection have become increasingly strict. In this context, choosing a suitable potting material has become the key to ensuring the stability of PCB performance and extending product lifespan. 01 Background and ChallengesWith the continuous advancement of intelligent car technology, electric tailgate has become an important component of high-end car configurations. The electric switch and closing function are precisely controlled through intelligent components such as Bluetooth sensors, therefore, the stability of the sensor PCB is crucial to the performance of the entire tailgate system. However, sensor PCBs must withstand various extreme conditions in the automotive environment during long-term use, including: Temperature changes: Vehicles operate under extreme temperature differences between high and cold temperatures, and sensors need to maintain stability.Vibration and shock: Frequent tailgate opening and closing operations and road vibrations may affect the mechanical stability of the PCB.Moisture and water boiling: Rainwater or humid environments may cause electronic components to become damp or short-circuit.Salt spray corrosion: Salt spray corrosion in coastal areas or during winter poses protection requirements for onboard electronic devices.02 Solution: EP 1713 two-component solvent-free ambient temperature curing epoxy sealantIn order to address the above challenges, EP 1713 two-component solvent-free ambient temperature curing epoxy sealant has become an ideal choice. This product has excellent adhesion, crack resistance, and thermal conductivity, making it very suitable for potting protection of electronic components. Below, we will analyze in detail the advantages…