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Integrated polymeric bonding, high-dielectric sealing, and high-tensile structural systems designed for electric vehicle powertrains, automotive sensor packaging, and high-voltage power electronics.
Modern electric vehicles demand unprecedented volumetric energy density, rapid high-C rate supercharging, and absolute fire safety. Thermally conductive insulating adhesives stand at the core of this engineering paradigm.
The global electric vehicle (EV) industry is experiencing a generational shift from conventional modular battery packs toward integrated Cell-to-Pack (CTP 3.0), Cell-to-Body (CTB), and Cell-to-Chassis (CTC) designs. By eliminating traditional mechanical modules, side brackets, and complex bolted assemblies, automotive OEMs achieve a 15% to 25% increase in pack volumetric efficiency and substantial weight savings.
However, this structural consolidation transfers immense mechanical and thermal responsibilities directly to polymer materials. In modern battery architectures, the insulating adhesive acts simultaneously as a structural fastener, a heat transfer bridge to the liquid cooling plate, and a high-voltage dielectric barrier. With the rise of 800V to 1000V platforms using Silicon Carbide (SiC) power switches and 4C/6C ultrafast charging, the risk of high-voltage partial discharge, dielectric breakdown, and localized thermal hotspots increases exponentially.
Balancing aggressive thermal conductivity with ultra-high electrical insulation and ductile mechanical bonding under harsh automotive thermal cycling (-40°C to +125°C).
Formulated with surface-modified spherical alumina and inorganic ceramic matrices that prevent electron avalanche. Ensures complete insulation between cell casings (at positive/negative potentials) and the grounded aluminum chassis cooling channel, eliminating leakage currents and electrochemical dendritic migration.
Optimized multimodal particle size distribution minimizes contact thermal resistance ($R_{th}$). Enables rapid heat conduction away from lithium-ion cell cores during peak discharge and extreme fast-charging cycles, maintaining pack temperature equilibrium within the optimal ±3°C operating delta.
Meets strict UL 94 V-0 flame retardancy standards without toxic halogens. Under extreme thermal runaway scenarios exceeding 800°C, the polymer forms a ceramified sacrificial char layer that isolates adjacent cells, dramatically delaying domino-effect fire propagation across the battery module.
Engineered cross-link density provides high tensile lap shear strength to structural aluminum (6000/7000 series), e-coated steel, and PET/PI cell wraps. Modulus is tuned to dampen multi-axis road vibrations (ISO 16750-3) and buffer lithium-ion expansion/contraction during 10-year service lifetimes.
Controlled thixotropy index and shear-thinning behavior allow effortless high-speed robotic dispensing (automated 2K dynamic mixing). Zero sagging on vertical cell walls, low press-in force requirements to avoid cell deformation, and guaranteed void-free interfacial wet-out.
Fully certified for RoHS, REACH, and VOC/siloxane outgassing standards. Demonstrates exceptional resistance to high-humidity aging (85°C / 85% RH for 1,000+ hours), thermal shock cycles (-40°C to +125°C), and corrosive automotive fluid splashes (coolants, oils).
| Polymer Chemistry Base | Thermal Conductivity (W/m·K) | Dielectric Strength (kV/mm) | Tensile Shear Strength (Al-Al) | Key EV Battery Application Focus |
|---|---|---|---|---|
| 2K Polyurethane (PU) Structural | 1.2 – 2.5 | > 22 kV/mm | 8.0 – 14.0 MPa | Prismatic / Blade CTP bottom structural bonding & side plate assembly |
| 2K Epoxy High-Strength Adhesive | 1.5 – 3.5 | > 25 kV/mm | 12.0 – 20.0 MPa | Rigid cell-to-chassis structural integration, IGBT & inverter heat sinks |
| Addition-Cure Silicone Gap Filler | 2.0 – 4.5 | > 18 kV/mm | 1.5 – 4.0 MPa (Elastic) | Cylindrical cell array potting (4680/21700), low-stress gap filling |
| Reactive Polyurethane (PUR) Hot Melt | 0.8 – 1.8 | > 20 kV/mm | 7.0 – 12.0 MPa | Rapid fixation of BMS enclosures, sensor brackets, and cable harness clips |
Customized polymeric adhesives solving structural integrity, electrical insulation, and heat conduction challenges from the individual cell level to full-scale power distribution systems.
In large-format prismatic and blade battery configurations, batteries are arrayed directly over liquid-cooling extrusion plates. Our insulating structural adhesives create a permanent, bubble-free thermal interface that bonds the bottom or side insulating PET foil of the cell to the cold plate.
By delivering high lap shear adhesion (>10 MPa) with tailored shear modulus, the adhesive absorbs differential thermal expansion between aluminum cooling plates ($\approx 23 \times 10^{-6}/\text{K}$) and battery can walls, preventing delamination and maintaining low thermal impedance over thousands of charging cycles.
For high-power cylindrical cell arrays, low-viscosity 2K silicone or lightweight polyurethane potting compounds are injected into inter-cell matrix voids. The compound provides 360-degree dielectric encapsulation, seals out moisture, dampens acoustic resonances, and conducts radial heat efficiently down to bottom snake tubes or base cooling plates.
The Battery Management System (BMS) monitors cell voltage, state-of-charge (SoC), and temperature sensors in real time. High dielectric PCBA fixing adhesives and conformal coatings protect sensitive trace layouts against electrochemical migration, condensation moisture, and tin-whisker short circuits.
Beyond the battery pack, high-power Silicon Carbide (SiC) MOSFETs, IGBT power modules, and planar transformers in OBCs generate dense localized heat fluxes. Our high-conductivity thermal adhesives bridge micro-gaps between ceramic substrates and cold sinks, ensuring stable operation under high switching frequencies and continuous 800V bus voltages.
Songxi provides state-of-the-art functional polymer material solutions designed to solve demanding adhesive, thermal, and dielectric challenges across global industries.
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.
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.
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.
Next-generation battery chemistry and circular economy regulations demand polymers with dual capabilities: permanent structural reliability in operation and controlled debonding during end-of-life recycling.
With global regulations enforcing high material recovery rates from spent EV battery packs, permanently unyielding structural adhesives pose a severe challenge for automated disassembly. Future insulating adhesives incorporate thermally triggered cleavage groups or electrically switchable ionic interfaces. When exposed to a specific thermal spike or voltage pulse at the recycling facility, the adhesive degrades cohesively without damaging raw aluminum casings or rare metal cells.
In alignment with Scope 3 carbon reduction initiatives by global tier-1 automotive suppliers, Songxi's laboratory is synthesizing plant-derived polyols and circular monomer feedstocks. These eco-friendly insulating adhesives deliver identical thermal conductivity (up to 3.0 W/m·K), dielectric breakdown ratings (>20 kV/mm), and UL 94 V-0 flame ratings while cutting product carbon footprints by up to 35%.
Explore our complete lineup of high-performance structural adhesives, dielectric sealants, and precision assembly polymers for electric vehicles, automotive lighting, and PCBA protection.
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.