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Engineered high-performance thermal conductive structural adhesives and dielectric potting formulations delivering superior heat dissipation, structural integrity, and flame retardancy for modern EV battery packs.
Explore our top-tier conductive adhesives and structural sealants specifically optimized to withstand extreme thermal fluctuations, structural vibration, and electrical breakdown risks in electric vehicle power modules.
The global electrification of transportation has driven automotive manufacturers and Tier-1 battery suppliers toward higher volumetric energy densities, faster charging rates (4C to 6C), and extended life cycles. At the heart of this electric vehicle (EV) revolution lies the power battery module and pack thermal management system (BTMS). As power densities escalate and battery architectures transition toward 800V high-voltage platforms, the performance requirements for thermally and electrically conductive adhesives have transitioned from secondary packaging aids to mission-critical structural materials.
Ultra-fast DC charging generates substantial localized joule heating inside battery cells, demanding thermal interface conductivity values reaching 2.0 to 4.5 W/m·K to prevent thermal runaway propagation.
Modular elimination in CTP and Cell-to-Chassis (CTC) designs requires adhesives to serve dual roles: transferring heat directly to liquid cooling plates while providing extreme lap shear adhesion (>10 MPa).
Higher voltage architectures necessitate high dielectric strength (>15 kV/mm) and partial discharge elimination to safeguard sensitive Battery Management System (BMS) electronics from breakdown.
Market studies project the global automotive thermal management adhesive sector to expand at a compound annual growth rate (CAGR) exceeding 18.5% over the next decade. This growth is predominantly anchored in the demand for two-component polyurethane (2K PU), epoxy, and silicone-based formulations that blend high thermal conductivity, low density for lightweighting, superior aging stability, and automated high-speed dispensing compatibility.
From prismatic cell side-plate bonding to cylindrical cell potting and cooling plate lamination, discover how our functional polymers solve complex heat transfer and structural bonding challenges.
In modern prismatic and blade battery assemblies, individual cells are adhesively bonded directly onto aluminum liquid cooling channels. This interface requires a thermal structural adhesive that offers zero voiding, low thermal contact resistance (Rth), and high peel strength. By replacing conventional mechanical fasteners with high-performance polyurethane or epoxy adhesives, automotive manufacturers achieve a 25% reduction in pack weight while establishing an uninterrupted thermal conduit that pulls heat away from cell cores during regenerative braking and high-speed acceleration.
High-density cylindrical battery modules (e.g., 21700 and 4680 configurations) rely on thermally conductive potting compounds to fully fill interstitial gaps between individual battery cells and bottom cooling serpentines. Our flame-retardant silicone and polyurethane potting compounds offer low initial viscosity for rapid air displacement, excellent self-leveling, and UL 94 V-0 flame rating. The cured elastomer absorbs dynamic road vibration, mitigates micro-fretting corrosion on nickel busbars, and serves as an effective fire-barrier buffer to halt cell-to-cell thermal propagation.
The Battery Management System (BMS) and power distribution units (PDU) are prone to electrochemical migration, high-voltage partial discharge, and moisture ingress. Applying high dielectric strength PCBA fixing adhesives and conformal coatings safeguards surface-mounted devices (SMDs) and solder pads against electrolytic corrosion while preventing parasitic high-voltage arc tracking across micro-pitch conductors.
| Adhesive Chemistry | Thermal Conductivity (W/m·K) | Tensile Shear Strength | Key Advantages in EV Battery Modules | Primary Application Target |
|---|---|---|---|---|
| 2K Structural Polyurethane | 1.5 – 3.0 | 8 – 15 MPa | Balanced elasticity, low density, high fracture toughness, primerless metal adhesion. | Cell-to-liquid cooling plate bonding, side plate bonding. |
| Thermally Conductive Epoxy | 2.0 – 4.5 | 12 – 22 MPa | Highest structural rigidity, superior chemical resistance, exceptional shear modulus. | Module end-plate structural bonding, IGBT heat sink attachment. |
| Low-Stress Silicone Gel / Potting | 1.0 – 2.5 | 1.0 – 3.5 MPa | Ultra-low modulus, extreme operating temp range (-50°C to +200°C), zero stress on solder joints. | Cylindrical cell array potting, BMS board potting. |
| Reactive Hot Melt (PUR) | 0.4 – 1.0 | 6 – 12 MPa | Instant green strength within seconds, high automated production throughput. | Insulating sheet bonding, sensor positioning, module cover assembly. |
Songxi Technology is a high-tech enterprise specializing in the R&D, production, and sales of electronic adhesives. Based on silicone, polyurethane, acrylic, and epoxy systems, we provide reliable bonding, sealing, and protection solutions for power electronics, optoelectronics, new energy, automotive, and aerospace industries.
We are committed to becoming a trusted provider of functional polymer material solutions for the electronics industry. Through continuous innovation and application development, we promote the localization of high-end electronic adhesives and help intelligent devices achieve greater stability and durability.
Delivering tailored material engineering from molecular formulation to high-volume automated manufacturing lines.
Songxi's business covers three functional areas: adhesive & sealing, potting & protection, and thermal interface materials. Our product portfolio includes PCBA fixing adhesives, UV adhesives, sealants, thermal conductive potting compounds, thermal greases, pads, two-component thermal gels, EMI shielding sealants, and reactive hot melt adhesives.
Our products serve power batteries, photovoltaic modules, drones, automotive electronics, 5G communications, and LED lighting. We provide both standard products and customized solutions for applications such as BMS conformal coating, IGBT thermal filling, and power battery structural bonding, supported by extensive technical experience and application expertise.
Led by a Ph.D. in Polymer Materials from Sichuan University, Songxi's R&D team has nearly twenty years of silicone application experience and has participated in over 100 product development projects. We maintain cooperation with research institutions including Chenguang Chemical Research Institute, Sichuan University, and Beijing Institute of Technology.
Certified with ISO9001, Songxi operates a comprehensive management system covering procurement, production, inspection, and after-sales service. Our products comply with RoHS and REACH requirements, with SGS verification and UL 94 V-0 flame retardant certification, ensuring consistent quality and reliable delivery.
Complete portfolio of optical, structural, potting, and reactive hot melt adhesives formulated for high reliability in electric vehicle powertrains, lighting, and electronic sub-assemblies.
Songxi adheres to integrity and quality throughout material selection, production, and delivery, turning reliability into a competitive advantage and earning long-term customer trust through professional service and continuous improvement across global markets.