Enhance Safety
Mitigate thermal runaway, fire risks, and environmental damage.
Battery Potting & Adhesives for E-Mobility:
Safety, Efficiency & Reliability
Protecting the Heart of Your EV: High-Performance Battery Pack Solutions
The battery is the most critical—and vulnerable—component in e-mobility systems. At Epic Resins, we engineer advanced polyurethane and epoxy potting compounds and adhesives to:
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Extend Battery Life
Protect against moisture, chemicals, and mechanical stress.
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Optimize Performance
Improve thermal management with UL-recognized, thermally conductive materials.
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Reduce Costs
Streamline production with consistent, easy-to-process materials.
Non-Cellular Elastomers: A Safer Alternative to Foam Potting
When it comes to batteries, the stakes are high. A single malfunctioning cell is capable of a thermal runaway event that can result in a fire or explosion. However, when safety is put at the #1 design element, Epic Resins potting solutions come out on top. Potting your battery with a non-cellular elastomer is far superior compared to traditional foam potting solutions. Unlike foam, which compromises your battery pack's structural integrity and thermal performance, our elastomers form a dense, rugged, uniform barrier that contains thermal events and reduces propagation.
Why non-cellular elastomers outperform foam:
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Superior flame propagation mitigation to prevent the spread of a thermal event
- Vibration and impact resistance due to its excellent adhesive properties
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Rugged structural integrity is suited for extreme environments
- Excellent moisture resistance to protect against corrosion
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Consistent, easy processing every time for high-volume production
- Strong thermal conductivity properties allow it to dissipate heat effectively
E-Mobility Battery Compounds
Epic S7253-01 is a two-component, UL 94 V-0 recognized polyurethane compound designed for electronic applications requiring encapsulation. The low weight loss of S7253-01 at elevated temperature suggests this product is suitable for applications that can reach up to 125°C. This material is currently utilized in a variety of applications, including automotive, that require thermal cycling between -40°C and 85°C. It features good thermal conductivity along with good adhesion to various metals and plastics. S7253-01 has been tested and meets ROHS requirements.
- Epic S7475 is a two-component polyurethane compound
- Designed for potting electronic control modules (ECM's) and a wide variety of electronic devices with an operating range of -50°C to 130C°C
- Low mixed viscosity allows the material to flow into intricate areas under printed circuit boards and other tight-tolerance areas
- 4:1 by volume mix ratio allows the system to be very adaptable for meter mix and dispense processing
- Very low hardness in combination with the low Tg provides excellent flexibility, allowing delicate surface-mounted devices (SMDs) to expand and contract during thermal cycling and thermal shock
- Has shown extremely low weight loss at 130°C, for applications that generate a great deal of heat
- UL 94-V0 recognized at 4.8 mm
- RoHS compliant
- S7524 is an unfilled UL 94 V-0 recognized polyurethane
- Low viscosity and easy 2:1 by volume mix ratio for high-volume production
- Various gel times and viscosities are available to work with a variety of battery pack and module configurations
- Lightweight formula and mid Shore A hardness
- Excellent in battery applications, providing mitigation of thermal runaway and its propagation within battery cells
- Epic S7527 is a UL 94 V-0 recognized polyurethane potting compound
- UL 94 V-0 flame rating
- RTI rating of 150°C per UL 746
- Designed for use in equipment conforming to UL 8750, the standard for LED equipment for use in lighting products
- Low mixed viscosity for superior flow into tight tolerance areas
- Excellent thermal and electrical properties
- Low weight loss at elevated temperatures
- Outstanding adhesion to various metal and plastic substrates
- RoHS compliant
- Excellent moisture resistance
| Viscosity: | 3,000 – 4,000 cps @ 25°C, 20 RPM |
| Hardness: | 88 – 92 Shore A @ 25°C |
- Epic S7553 is a two-component polyurethane compound
- Convenient 4:1 volumetric mix ratio
- UL 94 V-0 recognized at 6 mm
- RoHS compliant
- Designed for electronic potting applications, including: battery management systems, sensors, control modules & under-the-hood applications
- Epic S7633 is a black, two component polyurethane
- Designed to attain an RTI rating above 140C
- Great combination of low CTE & low Tg
- Convenient 4:1 volumetric mix ratio
- RoHS compliant
- UL 94 V-0 recognized at 9mm
- Applications include: battery packs, PCB potting, under-the-hood applications
- Epic S7634 is a 2-component polyurethane potting and encapsulating compound
- UL 94 HB & 94 V-0 flammability rating
- Free of halogens and tri-phenyl phosphate type flame retardants
- Designed for use across a broad temperature range of -40°C to 130°C
- Features a convenient 4:1 volumetric mix ratio and a low glass transition temperature
- Low viscosity for excellent flow into tight areas, making it ideal for Battery Management Systems, DC/DC converters, GPS sensors and other electronics requiring reliable protection
- Maintains flexibility, electrical stability, and low Tg, ensuring long-term performance in harsh environments
- RoHS compliant, helping manufacturers meet global environmental and safety standards
- Applications include: battery management systems, DC/DC converters, GPS sensors
- Epic S7593 is a two-component polyurethane encapsulant
- Designed to have a high thermal conductivity
- UL 94 V-0 at 1/2"
- Self-leveling and long pot life for ease of manufacturing
- Epic S7594 is a 2-component polyurethane potting compound
- Designed with a very high thermal conductivity, combined with a long gel time
- UL 94 V-0 recognized at a thickness of 12.5mm in screening tests
Custom Engineered Solutions for Your Exact Requirements
At Epic Resins, we don't just supply materials - we engineer performance. Our advanced polymer science capabilities allow us to create perfectly tailored epoxy and polyurethane formulations designed specifically for your e-mobility application's unique demands.
Why Custom Formulations Matter in E-Mobility
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Optimal performance in your specific operating environment
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Precise balance of thermal, mechanical and electrical properties
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Compliance with your industry's exacting standards
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Enhanced product lifespan and reliability
Your Partner in Advanced Material Solutions
Our team of polymer scientists works closely with you to:
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ANALYZE
your specific requirements
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DEVELOP
optimized formulations
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TEST
under real-world conditions
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DELIVER
production-ready materials
Let's create the perfect material solution for your e-mobility application.
