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.
CASE STUDY: Cylindrical Battery Packs in LEVs
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
- Currently used in a variety of applications, including automotive, that require thermal cycling between -40°C and 85°C
- Low weight loss at elevated temperatures suggests this product is suitable for applications that can reach up to 125°C
- Good thermal conductivity along
- Great adhesion to various metals and plastics
- Meets ROHS requirements
- View our Case Study.
- Epic S7475 is a two-component polyurethane compound
- Designed for potting electronic control modules and a wide variety of electronic devices
- Low mixed viscosity allows the material to flow into intricate areas under printed circuit boards and other tight tolerance areas
- 4:1 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 to expand and contract during thermal cycling and thermal shock
- Extremely low weight loss at 130°C, for applications that generate high heat
- UL 94 V-0 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 two-component polyurethane potting compound
- Formulated for applications requiring thermal stability at high temperatures
- UL 94V-0 flame rating and a 150°C RTI rating per UL 746
- Excellent for potting and encapsulating sensitive electronics which will be exposed to harsh environments
- Low mixed viscosity for superior flow into tight tolerance areas
- Good thermal conductivity
- Low weight loss at elevated temperatures
- Outstanding adhesion to various metal and plastic substrates
- RoHS compliant
- Excellent moisture resistance
- Epic S7553 is a two-component polyurethane compound
- Designed for electronic potting applications
- UL 94 V-0 recognized at 6-9 mm
- RoHS compliant
- Epic S7633 is a black, two component polyurethane
- Formulated for electrical potting applications
- Designed to attain an RTI rating above 140C
- UL 94 V-0 recognized at 9mm
- Epic S7634 is a 2-component polyurethane potting and encapsulating compound
- UL 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
- 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 two-component polyurethane potting compound
- Designed with a very high thermal conductivity combined with a long gel time
- Formulated to meet a UL 94 V-0 at 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.