Battery Potting and Adhesives for E-Mobility
Reduce cost and increase productivity with Polyurethane & Epoxy materials
The battery is the most important component in an electric vehicle. Reliability, cost and safety are top priorities when designing your battery for E-Mobility. We partner with you, providing materials that protect your battery against moisture, thermal runaway, chemicals, mechanical shock and other environmental stresses.
Increase the efficiency and life of your battery packs with our thermally conductive, UL recognized potting compounds. We formulate and manufacture epoxy and polyurethane battery potting compounds as well as lightweight adhesives.
Non-Cellular Elastomer: A Safer Alternative to Foam Potting
When safety is non-negotiable, Epic Resins' non-cellular elastomer potting materials offer a superior solution compared to traditional foam potting. Unlike foam, which can allow flame and heat to pass through, our elastomers form a dense, uniform barrier that helps contain thermal events and reduce propagation.
CASE STUDY: Cylindrical Battery Packs in LEVs
Why non-cellular elastomers outperform foam:
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More effective at blocking flame, heat, and gas transfer between cells
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Maintain structural integrity under thermal and mechanical stress
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Reduce risk of thermal runaway propagation
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More rugged strength than a foam
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Seamlessly integrates into standard battery assembly processes
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 temperatures 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. View our Case Study.
S7524 is an unfilled UL 94 V-0 recognized polyurethane. It has a 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. The formula is lightweight and offers a mid Shore A hardness. S7524 is 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. S7527 carries a UL 94V-0 flame rating and a 150°C RTI rating per UL 746. Epic S7527 is excellent for potting and encapsulating sensitive electronics which will be exposed to harsh environments.
Epic S7475 is a two-component polyurethane compound 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. A 4:1 mix ratio allows the system to be very adaptable for meter mix and dispense processing. The very low hardness of S7475 in combination with the low Tg provides excellent flexibility, allowing delicate surface-mounted devices to expand and contract during thermal cycling and thermal shock. For applications that generate high heat, S7475 has shown extremely low weight loss at 130°C. It is UL 94 V-0 recognized at 4.8 mm and is RoHS compliant.
Epic S7593 is a two-component urethane thermally conductivity self-leveling encapsulant. EPIC S7593 is designed to have a high thermal conductivity, 94-V0 at 1/2" and long pot life for ease of manufacturing.
Epic S7594 is a two-component urethane potting compound designed with a very high thermal conductivity combined with a long gel time. S7594 has been formulated to meet a UL 94 V-0 flame rating at a thickness of 12.5mm in screening tests.
S7634 is a high-performance UL 94 V-0 recognized polyurethane potting compound. It was formulated for demanding electronic applications. This 2-component system features 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. Designed for use across a broad temperature range of -40°C to 130°C, S7634 maintains flexibility, electrical stability, and low Tg, ensuring long-term performance in harsh environments. With a 4:1 volumetric mix ratio and a formulation free of halogens and triphenyl phosphate-type flame retardants, S7634 offers safe, effective encapsulation. It is also RoHS compliant, helping manufacturers meet global environmental and safety standards.
Custom Formulated Materials
No matter your application requirements, we are ready to create a quality custom epoxy and polyurethane formulation to meet your specs. Our advanced development, testing, and production facility, ensures you will receive a polymer that is perfectly formulated for your application. Whether you need lamination epoxy, reaction-injection molding polymers, or filament-winding encapsulation materials, we'll create the best formulation for you.