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High-performance functional coatings and adhesives engineered for EV battery pack structural isolation, thermal dissipation, and harsh environmental protection.
High-grade dielectric resistance and moisture barrier for battery management electronics.
UL 94 V-0 certified two-component elastomer for thermal transfer and shock absorption.
High-strength cell-to-pack adhesive offering moisture seal and thermal bridge integration.
Breakdown voltage rating >25 kV/mm with outstanding thermal stability across -50°C to 180°C.
The electric vehicle (EV) sector is undergoing a massive paradigm shift. As Original Equipment Manufacturers (OEMs) migrate from legacy 400V battery architectures to 800V and even 1000V ultra-fast charging platforms, the thermal dissipation demands and electrical isolation standards for traction battery modules have escalated exponentially. In this high-density environment, protective coatings for EV power battery module thermal management are no longer merely passive environmental barriers—they have evolved into active, multi-functional material solutions critical to vehicle safety, volumetric efficiency, and thermal runaway prevention.
Modern battery coatings act as primary barriers against thermal propagation. When an isolated cell fails, high-temperature ceramic-filled polymer coatings delay cascade failures by providing localized heat shielding and preventing electrical arcing across adjacent cells.
Eliminating physical intermediate module casings increases energy density but removes mechanical buffers. Thin-film dielectric coatings and thermal interface sealants replace bulky mica plates and plastic frames, providing direct galvanic isolation and thermal coupling to cooling plates.
EV batteries endure cyclic automotive vibrations, road salt spray, condensation from ambient thermal cycling, and high-frequency EMI noise. Formulations must maintain elasticity, adhesion, and dielectric strength without microcracking over a 15-year vehicle lifespan.
Protective coatings serve multiple distinct operational roles across the entire anatomy of an automotive battery pack, from cell level to electronic management systems.
In high-density battery arrays, bare aluminum cell casings must be isolated from neighboring cells and structural side plates. Traditional blue PET wrap films are increasingly replaced by automated spray-applied or dip-applied UV-cure/polyurethane dielectric coatings. This automated process ensures uniform film thickness (80–150 μm), complete edge coverage without air bubbles, and thermal resistance up to 200°C, eliminating short-circuit pathways during dynamic mechanical deformation.
Battery Management System (BMS) PCBAs operate in close proximity to high-current busbars and cooling channels. Humidity condensation and atmospheric sulfur can lead to dendritic short circuits. Songxi’s conformal coatings provide high moisture-vapor barrier qualities, solvent resistance, and low ionic contamination, preserving sensor precision and communication integrity across CAN-bus and daisy-chain architectures.
The boundary between the battery cell bottom and the aluminum extruded liquid cold plate requires an interface material with both high thermal conductivity and supreme dielectric isolation. Two-component polyurethane and silicone thermal gels provide zero-stress gap filling, accommodate manufacturing tolerances, and ensure continuous heat dissipation during peak DC fast-charging cycles.
| Performance Parameter | Polyurethane System | Silicone System | Epoxy / Acrylic System |
|---|---|---|---|
| Dielectric Strength | 22 – 30 kV/mm | 20 – 25 kV/mm | 25 – 35 kV/mm |
| Thermal Conductivity | 1.5 – 3.5 W/m·K | 1.8 – 4.5 W/m·K | 0.8 – 2.0 W/m·K |
| Operating Temperature | -40°C to 130°C | -50°C to 200°C | -40°C to 150°C |
| Elongation at Break | 50% – 200% | 100% – 300% | 5% – 20% |
| Flame Retardancy | UL 94 V-0 | UL 94 V-0 | UL 94 V-0 / V-1 |
| Primary EV Application | CTP Bonding & Bottom Cold Plate Coating | High-Voltage BMS Potting & Busbar Insulation | Stator Impregnation & Hard Dielectric Barriers |
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.
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'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.
We work in direct partnership with tier-1 battery suppliers to formulate specialized chemical systems tailored to specific dispensing cycles, thixotropic viscosities, room-temperature or low-temperature accelerated cures, and stringent automotive volatile organic compound (VOC) standards.
State-of-the-art synthetic facilities, precision analytical instruments, and automated manufacturing systems ensuring unmatched coating consistency.
Precision planetary mixing guaranteeing bubble-free high-viscosity thermal coating compounds.
Uniform dispersion of micro- and nano-ceramic thermal fillers for ultra-high conductivity.
Automated verification of insulation resistance and AC/DC breakdown limits up to 50 kV.
Accurate isotropic thermal conductivity testing across broad automotive temperature ranges.
Precision atomization and film dispensing tailored for high-volume EV BMS manufacturing.
-60°C to 180°C rapid cycle validation ensuring crack-resistant performance over pack lifetime.
Real-time shear rate monitoring to ensure optimal slump resistance and gap penetration.
Guaranteed ionic purity for semiconductor, BMS, and high-voltage contact 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.