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High-reliability functional polymer solutions designed for high-density power electronics, solar junction enclosures, and harsh-environment thermal dissipation.
As photovoltaic modules escalate in wafer dimensions (M10, G12) and system voltages reach 1500V DC, junction box potting materials serve as the frontline defense against thermal runaway and catastrophic dielectric breakdown.
The photovoltaic junction box is the vital nerve center of any solar module, housing electrical connections and critical bypass diodes (Schottky or planar). When shading, soiling, or localized cell mismatch occurs, the bypass diode enters forward-bias conduction mode to prevent cell hot-spot destruction. In high-power modules exceeding 600W to 700W, the continuous current through the diode can exceed 15A to 30A, generating localized temperatures in excess of 130°C to 160°C inside a compact enclosure.
Without an advanced thermally conductive potting epoxy, this concentrated heat cannot escape the sealed junction box. Diode junction temperatures (Tj) soar toward their critical thresholds (typically 175°C), resulting in thermal degradation, elevated reverse leakage current, solder reflow, and eventual catastrophic module failure. Our specialized epoxy potting systems feature customized micro-scale alumina and aluminum nitride filler matrices that rapidly channel heat away from the diode substrate to the external casing, keeping diode operating temperatures safely beneath 95°C.
Formulating an industrial-grade epoxy potting compound for PV junction boxes requires balancing thermal dissipation, electrical isolation, rheology, and climatic durability.
High thermal bulk conductivity (1.2 to 2.5 W/m·K) paired with exceptionally low thermal boundary resistance ensures continuous heat evacuation from bypass diodes and electrical terminal busbars.
Dielectric strength exceeding ≥25 kV/mm and Comparative Tracking Index (CTI) > 600V (PLC 0), completely mitigating high-voltage partial discharge, arc tracking, and corona degradation.
Near-zero moisture vapor transmission rate (MVTR) and exceptional hydrolytic stability prevent water ingress, salt-spray corrosion, and delamination even under damp-heat aging (85°C / 85% RH for 3,000+ hours).
Formulated with eco-friendly, halogen-free flame-retardant chemistry, extinguishing open flames within 10 seconds without flaming drips, safeguarding rooftop and ground installations against fire hazards.
Primerless, tenacious bonding to Polyphenylene Oxide (PPO), Polyphenylene Ether (PPE), copper leads, tin-plated copper, and silicon solar backsheets, eliminating micro-gap debonding under thermal cycling (-40°C to +105°C).
Optimized thixotropic index, low initial mixed viscosity, and exceptional self-leveling behavior ensure bubble-free potting through automated Meter-Mix-Dispense (MMD) lines without damaging delicate lead frames.
| Performance Parameter | Modified Potting Epoxy | Traditional Silicone Gel | Standard Polyurethane (PU) |
|---|---|---|---|
| Mechanical Rigidity & Impact Resistance | High (Shore D 65 - 85), robust crush protection | Low (Shore 00 / Shore A), soft and gel-like | Medium (Shore A 70 - Shore D 50) |
| Moisture Vapor Transmission Rate (MVTR) | Extremely Low (< 5 g/m²·24h) — Superior Barrier | Moderate to High (Permeable to water vapor) | Low to Moderate (Prone to hydrolytic aging) |
| Thermal Conductivity Range (W/m·K) | 1.0 – 2.5 W/m·K (Highly loaded) | 0.8 – 2.0 W/m·K | 0.5 – 1.2 W/m·K |
| Adhesion to PPO / PPE Junction Box Plastics | Superior (Chemical & mechanical interlock) | Poor without specialized silane primers | Good, but degrades under damp heat |
| High-Voltage Partial Discharge Elimination | Excellent (≥25 kV/mm, no internal voids) | Excellent (≥20 kV/mm) | Moderate (Prone to micro-bubbles) |
| Flammability Rating | UL 94 V-0 Certified | UL 94 V-0 / V-1 | UL 94 V-0 / HB |
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.
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.
Select from our benchmark formulations engineered for renewable energy infrastructure, high-voltage equipment, and advanced aerospace electronics.
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.