How to Select Potting Compounds for Automotive Pressure Sensors: Different Design Philosophies for Core‑Element Protection vs Housing Sealing

When selecting adhesives for automotive pressure sensors, simply searching for “high‑temperature waterproof potting compound” is not sufficient. You need to break down the structure into sensing core element, PCB/leads, housing, pin terminals and media‑contact zones. For the core element, low‑stress performance and long‑term stability are prioritized. For housing sections, adhesion and sealing stand as key requirements. For full‑cavity potting, flowability, insulation and thermal‑cycle resistance must also be taken into account. ELAPLUS sensor‑oriented solutions separate oil‑resistant sealing, pin‑terminal sealing, FPC fixation, ceramic‑substrate bonding and overall potting, instead of adopting one single material for all positions. Pressure Transmitter Table: Adhesive Selection for Different Zones of Pressure Sensors Application Position Primary Task Key Considerations Selection Direction Pressure‑sensing core Sensitive‑component protection Low stress, electrical insulation Flexible silicone / gel Ceramic substrate Component fixation Adhesion, low shrinkage Silicone / epoxy resin Pin terminals Waterproof sealing Flow property, adhesion Sealant PCB assembly Moisture‑proof protection Insulation, stress relief Potting compound / Conformal coating Aluminum‑plastic hybrid housing Housing sealing Dissimilar‑substrate bonding Sealing silicone Full cavity potting Overall encapsulation Flowability, insulation, temperature resistance Epoxy / Polyurethane / Silicone Temperature‑Pressure Sensor Core: SIPC 1835 SIPC 1835 is specified for temperature‑pressure sensor cores with a mixing ratio of 10:1 and a cure time of approx. 1‑2 hours. The priority here is not excessive potting thickness, but to protect the core element while introducing minimal mechanical constraints to it. Housing Sealing: SIPC 1810 LV SIPC 1810 LV can be evaluated for sensor housing sections, engineered for sealing and bonding between aluminum housings and plastic parts. It clearly illustrates a typical rule for pressure sensors: core‑protection adhesive ≠ housing‑sealing adhesive. Why Are Pressure Sensors Vulnerable to High‑Stress Loads? Differential‑pressure sensor Pressure sensors measure extremely tiny deformation or pressure variations. Large curing shrinkage or excessive hardness from potting materials may introduce extra mechanical load…