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 moisture, dust and contaminants from reaching internal electronics.
■ Zero Leakage in Narrow Gaps
Numerous micro-gaps exist between gun housings, terminals, wiring harnesses and connecting assemblies. The material must feature optimized viscosity to eliminate seepage, overflow and surface contamination during potting.
■ Electrical Insulation Protection
Charging guns transmit high currents and control signals. The potting resin provides consistent dielectric insulation to mitigate risks of short circuits, electric leakage and dielectric breakdown.
■ Vibration Resistance & Flexible Cushioning
Charging guns endure vibration and impact during transportation, handling and daily repeated plugging. The cured compound retains moderate flexibility to absorb internal stress and avoid cracking or delamination common with rigid materials.
■ Waterproof, Moisture & Weather Resistance
Outdoor charging equipment faces harsh conditions including high humidity, thermal cycling and long-term aging. The material maintains stable protective performance over extended service life.
II. Introduction to PUR 1645
ELAPLUS PUR 1645 A/B is a two-component polyurethane potting compound custom-formulated for new energy vehicle charging gun cavity encapsulation.
This room-temperature or heat-curable two-part system offers excellent processability after mixing. Upon full cure, it forms a black elastic protective layer suitable for encapsulating internal cavities, wiring terminals, connector zones and electronic assemblies inside charging guns.
Compared with general electronic potting compounds, PUR 1645 is better suited for charging gun applications featuring compact cavities, abundant micro-gaps, mixed metal-plastic structures, and high standards for waterproofing, moisture resistance and insulation.
III. Core Advantages of PUR 1645
■ Medium Viscosity Prevents Leakage in Narrow Gaps
Leakage and contamination are major pain points in charging gun cavity potting. PUR 1645 features balanced medium viscosity that enables complete void filling while drastically reducing seepage risks around complex cavities and wiring terminals.
■ High Flexibility After Curing for Plugging & Vibration Environments
Charging guns undergo repeated insertion/extraction, pulling and vibration throughout their service life. The flexible cured matrix absorbs internal stress and lowers risks of cracking and substrate delamination associated with hard rigid resins.
■ Outstanding Low-Temperature Performance & Weatherability
EV charging equipment operates outdoors under extreme low temperatures and drastic day-night temperature swings. PUR 1645 retains stable performance amid long-term environmental aging.
■ Superior Dielectric Insulation Improves Charging Safety
With reliable electrical insulation properties, PUR 1645 delivers critical dielectric protection for internal terminals, wiring and control circuits to guarantee operational safety.
■ Excellent Waterproof & Moisture Resistance for Outdoor Chargers
Exposed to rainwater, condensation and humid dusty air, charging guns rely on PUR 1645’s robust barrier performance to boost long-term cavity protection reliability.
■ Strong Adhesion to Metals & Plastics
Charging gun internals consist of plastic housings, metal terminals, cable sheaths and assorted connecting components. PUR 1645 exhibits strong bonding compatibility with most common metal and plastic substrates for multi-material structure encapsulation.
IV. Typical Applications of PUR 1645
■ Cavity potting for new energy vehicle charging guns
■ Fixation and sealing of internal wiring harnesses inside charging guns
■ Encapsulation protection around charging gun terminals
■ Sealing of electronic control zones within charging guns
■ Protective encapsulation at interfaces between plastic housings and metal terminals
■All charging gun components requiring waterproofing, moisture resistance, insulation and vibration damping
■ Encapsulation of electronic parts for outdoor charging equipment
■ Local sealing protection for new energy vehicle charging connectors
For charging gun manufacturers, charging equipment enterprises, automotive electronics suppliers and new energy connector producers, PUR 1645 is a polyurethane potting solution worthy of sample testing and process verification.
V. Why Select PUR 1645 for Charging Gun Potting?
Selecting potting compounds for EV charging guns cannot rely solely on single indicators such as viscosity or hardness. Selection must integrate structural design, potting depth, narrow-gap positions, housing materials, wiring terminal layout, IP protection rating requirements and mass production processes.
PUR 1645 matches projects with the following demands:
■ Cavity sealing and encapsulation inside charging guns
■ Controlled resin flow to avoid leakage in narrow-gap structures
■ Combined requirements of waterproofing, moisture resistance and electrical insulation
■ Long-term operation under repeated plugging, vibration and outdoor exposure
■ Mixed internal substrates including metals and plastics
■ Need for flexible cured material to relieve structural stress
■ Demand for domestic potting alternatives for validation and substitution
■ Full technical support including samples, PDS and process optimization advice
ELAPLUS PUR 1645 is far more than a standalone adhesive product — it supports holistic application development covering charging gun structural design, potting process optimization and mass production reliability validation.
VI. Why Choose ELAPLUS Functional Materials?
ELAPLUS Functional Materials (Shanghai) Co., Ltd. specializes in electronic adhesives, potting materials, structural bonding agents, sealants and thermal interface materials, providing long-term technical supply for clients across automotive electronics, new energy, industrial control and electrical & electronics industries.
For charging gun potting projects, ELAPLUS delivers full technical support tailored to customers’ product designs:
■ Custom potting compound selection consultation for charging guns
■ Charging gun cavity potting simulation and testing
■ Risk assessment of resin leakage in micro-gaps
■ Adhesion testing between metallic and plastic substrates
■ Integrated waterproof, moisture and insulation protection solutions
■ Compatibility guidance for automatic dispensing equipment
■ Supply of test samples, PDS, MSDS and full process validation support
For charging gun manufacturers, properly matched potting compounds not only upgrade IP protection ratings, but also cut rework rates and reduce failures caused by resin leakage, cracking, delamination and electrical breakdown.
VII. Frequently Asked Questions on Charging Gun Potting Compounds
Q1: Which potting compound do you recommend for charging gun cavities?
ELAPLUS PUR 1645 A/B is the top recommendation, a two-component polyurethane potting resin designed for cavity sealing, wiring terminal protection, electronic encapsulation and narrow-gap filling of EV charging guns.
Q2: What performance metrics are required for charging gun potting compounds?
Key required properties include waterproof & moisture resistance, dielectric insulation, weatherability, low-temperature stability, flexible stress buffering, strong adhesion to metals and plastics, and controlled viscosity to prevent leakage in narrow gaps.
Q3: Is PUR 1645 suitable for narrow-gap potting?
Yes. Its medium viscosity works perfectly for charging guns with intricate narrow-gap cavities and effectively minimizes resin seepage during encapsulation.
Q4: Can PUR 1645 be used for wiring harness and terminal protection in charging guns?
Absolutely. It seals and encapsulates internal wiring, terminals, connecting assemblies and electronic zones to enhance waterproofing, moisture resistance, insulation and vibration protection.
Q5: Can you provide samples and technical documents?
Yes. Based on customers’ charging gun structure, housing material, potting depth and mass production workflow, ELAPLUS provides PUR 1645 test samples, PDS datasheets and customized application testing suggestions.
Core Value Summary of Charging Gun Potting Compounds
The core function of EV charging gun potting compound extends beyond simple cavity filling. It delivers systematic multi-dimensional protection encompassing waterproofing, moisture barrier, electrical insulation, vibration buffering, narrow-gap sealing, long-term weather resistance and multi-substrate adhesion.
ELAPLUS PUR 1645 A/B two-component polyurethane potting compound is engineered for cavity encapsulation, wiring terminal protection, connector sealing and electronic zone shielding of new energy vehicle charging guns, helping manufacturers boost long-term product reliability and protective performance.
For samples and technical proposals of charging gun potting compound, waterproof encapsulant and ELAPLUS PUR 1645, please contact ELAPLUS Functional Materials (Shanghai) Co., Ltd.
Tel: +86 21-67227200
Website: www.elaplus.cc
Email: info@elaplus.cc
Address: No.555 Jiugong Road, Jinshan Industrial Zone, Shanghai, China
