TEDA new energy vehicle battery pack potting glue: UL94 V-0/IP67 dual certification process detailed explanation

In the rapid development of new energy vehicles, as one of the core components, its performance and safety directly determine the quality and user experience of the entire vehicle. As a key material, potting glue plays an irreplaceable role in the protection, heat dissipation and earthquake resistance of the battery pack. As an industry-leading material solutions provider, TEDA’s new energy vehicle battery pack potting glue has successfully passed the UL94 V-0 flame retardant grade certification and IP67 protection grade certification with its excellent performance and strict process control, becoming a benchmark product on the market.

This article will start from the basic concept of potting glue and deeply explore the material characteristics, process flow of TEDA potting glue and the core requirements of UL94 V-0 and IP67 certification. At the same time, we will combine relevant domestic and foreign literature and experimental data to comprehensively analyze the technical advantages and application prospects of this product. Whether you are an engineer, R&D or an ordinary reader who is interested in the new energy vehicle industry, this article will provide you with a detailed technical guide and practical reference.

What is potting glue? Its importance in new energy vehicles

Polters are polymer materials specially used for electronic components and module packaging. Their main function is to protect internal components and prevent external environmental factors (such as moisture, dust, vibration, etc.) from causing damage to them. In the field of new energy vehicles, potting glue is widely used in the packaging of battery management systems (BMS), electronic control units (ECUs) and battery modules. The working environment of these components is usually harsh and needs to withstand various extreme conditions such as high temperature, low temperature, humidity, salt spray, etc., so it puts forward extremely high requirements for the performance of potting glue.

The main functions of potting glue

1. Waterproof and dustproof
   Potting adhesive can form a dense protective layer that effectively isolates moisture and dust and ensures that the battery pack operates normally in complex environments. For example, when a vehicle is driving on rainy days or muddy road conditions, potting can prevent water vapor from entering the inside of the battery and avoid short circuits or other failures.

2. Shock-resistant buffer
   During the vehicle’s driving, the battery pack will be subjected to vibration and impact from the road surface. Potted glue has good elasticity and can absorb and disperse these external forces to a certain extent, thereby protecting the internal components from damage.

3. Heat conduction and heat dissipation
   New energy vehicle batteries will generate a large amount of heat during charging and discharging. If they cannot be dissipated in time, it may lead to heat loss or even fire and explosion. High-quality potting glue not only has good thermal conductivity, but also can pass through its own fluidity.Distribute heat evenly to help the battery stay within a safe operating temperature range.

4. Electrical Insulation
   Potting adhesives usually have excellent electrical insulation properties, which can effectively prevent current leakage and ensure the stability and safety of the battery system.

5. Fire retardant and fireproof
   With the frequent occurrence of new energy vehicle accidents, consumers are paying more and more attention to battery safety. The flame retardant performance of potting adhesives has become one of the important indicators for measuring their quality. By adding specific flame retardants, potting can delay combustion speed when a fire occurs, and buy more escape time for occupants.

Industry background and development status

In recent years, with the advancement of the global carbon neutrality goal, the new energy vehicle industry has ushered in explosive growth. According to data from the International Energy Agency (IEA), global electric vehicle sales exceeded 10 million units in 2022, an increase of nearly 60% year-on-year. At the same time, the advancement of battery technology has also promoted the rapid development of the potting rubber market. According to statistics, the global potting rubber market size has reached billions of dollars in 2023, and it is expected to continue to maintain a double-digit growth rate in the next five years.

However, the surge in market demand has also brought higher technical barriers. Regulations of various countries have become increasingly strict in the safety requirements of new energy vehicles, especially in terms of the flame retardant performance and protection level of battery packs. For example, the UL94 standard formulated by the American Insurer Laboratory (UL) has become an important basis for measuring the flame retardant properties of materials; while the IP67 protection level is regarded as a basic requirement for the waterproof and dustproof capability of the battery pack. In this context, developing potting products that meet these high standards has become the goal that major manufacturers are competing to pursue.

Next, we will focus on the technical characteristics of TEDA new energy vehicle battery pack potting glue and its performance in UL94 V-0 and IP67 certification.

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Analysis of material characteristics and parameters of TEDA potting adhesive

TEDA potting glue uses advanced epoxy resin substrate formula, combining high-performance additives and optimized processes, making it outstanding in multiple dimensions such as flame retardancy, mechanical strength, thermal conductivity and weather resistance. The following will provide detailed explanations from three aspects: material composition, physical and chemical characteristics and specific parameters.

Material composition and structural design

TEDA potting glue consists of the following main components:

1. Epoxy resin matrix
   Epoxy resin is known for its excellent bonding strength, chemical corrosion resistance and thermal stability, and is an ideal substrate for potting glue. TEDA uses high-purity epoxy resin as the main chain material to ensure the basic performance of the product.

2. Inorganic filler
   In order to improve thermal conductivity and reduce shrinkage, TEDA added an appropriate amount of inorganic fillers (such as alumina, boron nitride, etc.) to the formulation. These fillers not only enhance the heat conduction ability of the material, but also give it better impact resistance and dimensional stability.

3. Flame retardant
   Flame retardants are a key ingredient in achieving UL94 V-0 certification. TEDA adopts an environmentally friendly phosphorus flame retardant to meet strict flame retardant requirements by inhibiting flame propagation and reducing smoke release.

4. Curifying agents and catalysts
   The choice of curing agent directly affects the final performance of the potting adhesive. TEDA uses modified amine curing agents and is combined with high-efficiency catalysts to ensure rapid curing of the material at room temperature or heating conditions, while taking into account flexibility and hardness.

Physical and Chemical Characteristics

The physical and chemical characteristics of TEDA potting glue are shown in the following table:

Features	Unit	Numerical Range	Remarks
Density	g/cm³	1.2 – 1.4	Slightly different depending on the specific model
Viscosity	mPa·s	500 – 2000	Wide adjustable range, adapting to various construction needs
Current time	min	20 – 60	Currect or heating at room temperature
Hardness (Shaw D)	—	70 – 80	Providing good wear resistance
Tension Strength	MPa	≥15	Strong tensile resistance
Elongation of Break	%	≥50	Have a certain degree of flexibility
Thermal conductivity	W/(m·K)	1.0 – 2.5	Efficient heat dissipation
Flame retardant grade	—	UL94 V-0	Complied with high flame retardant standards
Voltage Withstand Strength	kV/mm	≥20	Excellent electrical insulation performance

From the above table, it can be seen that all indicators of TEDA potting adhesives are at the industry-leading level, especially in terms of thermal conductivity and flame retardant grade. This balanced design enables the product to meet the needs of different application scenarios.

Parameter comparison and competitive advantage

In order to better understand the advantages of TEDA potting glue, we compared it with similar products from other mainstream brands, and the results are shown in the table below:

Brand/Model	Density (g/cm³)	Thermal conductivity (W/m·K)	Fire retardant grade	Price (USD/kg)
TEDA Series A	1.3	2.0	UL94 V-0	15
Brand X B Series	1.2	1.5	UL94 HB	12
Brand Y C Series	1.4	1.8	UL94 V-2	18
Brand Z D Series	1.5	2.2	UL94 V-0	25

It can be seen from the table that although some competitors may be slightly better in single indicators, TEDA potting glue stands out with its comprehensive performance balance and high cost-effectiveness. Especially in terms of flame retardant grade, TEDA has reached the high UL94 V-0 standard, far exceeding other brands.

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UL94 V-0 certification: the ultimate pursuit of flame retardant performance

UL94 standard is a set of materials flame retardant performance testing specifications formulated by Underwriters Laboratories, which are widely used in plastics, rubbers, coatings and other fields. Among them, the V-0 level represents a high-grade flame retardant performance, which means that the material can be extinguished quickly after being ignited by flame without continuously dripping the combustible substance. For new energy vehicle battery packs, choosing potting glue that meets the UL94 V-0 standard is crucial because it is directly related to the overall safety of the vehicle.

Overview of UL94 V-0 Test Method

The specific steps of UL94 V-0 testing include the following stages:

1. Sample Preparation
   Made the material to be tested into a bar sample of standard size (usually 125mm x 13mm x thickness) and ensure a smooth and smooth surface.

2. Flame exposure
   Use a gas blowtorch to apply a flame of a specified height and time (usually 10 seconds or 30 seconds) to the lower end of the sample to observe its combustion behavior.

3. Off time record
   Testers need to accurately record the time it takes for the flame to go out and whether secondary combustion occurs.

4. Drip Assessment
   If the material produces drips during combustion, further confirmation is required whether these drips ignite the cotton pad below.

The material can only obtain V-0 certification if all test results meet the following conditions:

• The extinguishing time after a single flame exposure shall not exceed 10 seconds;
• The extinguishing time after two flame exposure is not more than 50 seconds;
• No drips igniting cotton pads;
• There is no penetrating ablation on the surface of the sample.

Fire retardant mechanism of TEDA potting adhesive

The reason why TEDA potting glue can successfully pass the UL94 V-0 certification is due to its unique flame retardant system design. The following are its main flame retardant mechanisms:

1. Free Radical Capture
   Phosphorus flame retardant decomposes under high temperature conditions to form phosphate esters compounds, which can effectively capture free radicals in the flame and interrupt the combustion chain reaction.

2. Carbonized layer formation
   When the material is attacked by flame, the flame retardant creates a dense carbonized protective film on the surface. This film not only can isolate oxygen, but also significantly reduce the heat transfer rate, playing a “firewall”.

3. Smoke Suppression
   TEDA potting glue also contains special smoke inhibitors, which can reduce toxic gases and thick smoke generated during combustion and improve the safety of the escape environment.

Experimental verification and data analysis

To verify the actual flame retardant effect of TEDA potting glue, the researchers conducted multiple repeated tests and recorded the following key data:

Test items	Experimental Conditions	Result
Flame extinguishing time	10 seconds of single flame exposure	Average is 2.3 seconds, maximum value does not exceed 5 seconds
Dripping ignition situation	Place standard cotton pads below	No drip ignition was found
Smoke release	Measure with optical density meter	About 30% less than traditional potting glue
Temperature rise curve	Tested under simulated battery thermal runaway	The large temperature rise is controlled within 200℃, which is far below the risk threshold

The above data shows that TEDA potting glue performs excellently in all flame retardant performance indicators, fully meeting or even exceeding the requirements of the UL94 V-0 standard.

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IP67 certification: dual guarantee of protection performance

In addition to flame retardant performance, new energy vehicle battery packs also need to have strong waterproof and dustproof capabilities to cope with various complex working conditions. IP67 protection level is the standard set for this, where “6” means complete dust preventionEnter, “7” means that it can stay in a certain depth of water for a short time without being damaged. IP67 certified TEDA potting adhesive provides a comprehensive protection solution for battery packs.

Analysis of IP67 test method

IP67 test mainly includes the following two parts:

1. Dust Protection Test
   The sample was placed in a closed box filled with talc or other fine particles and stirred for more than 8 hours. After the test is completed, check whether there is dust invasion inside the sample.

2. Waterproof Test
   Immerse the sample in water at a depth of at least 1 meter and a time of not less than 30 minutes. Then remove and check the sample for water leakage or abnormal function.

Protection principle of TEDA potting adhesive

TEDA potting glue achieves IP67-level protection performance through the following methods:

1. Densified structure
   After curing, the potting glue forms a continuous three-dimensional network structure with almost no pores or defects, thus effectively blocking the penetration of moisture and dust.

2. Low water absorption rate
   Special formula design reduces the water absorption rate of TEDA potting glue to a low (usually less than 0.1%), and its performance will not be affected even if it is exposed to water for a long time.

3. Bonding Strength
   A firm bonding interface is formed between the potting glue and the battery case and other components to avoid gaps caused by vibration or thermal expansion and contraction.

Experimental verification and data analysis

To verify the IP67 protection performance of TEDA potting glue, the researchers designed a series of rigorous testing solutions, and some of the results are as follows:

Test items	Experimental Conditions	Result
Dust Protection Test	Talc powder concentration 1kg/m³, lasting for 8 hours	No dust residue inside the sample
Waterproof Test	The water depth is 1.5 meters, soaking time is 60 minutes	The sample is completely dry,Function is normal
Cycling temperature and humidity test	Temperature -40℃ to 85℃, relative humidity 95%, cycle 10 times	The appearance of the potting glue has no change and its performance is stable

These data fully demonstrate the reliability and durability of TEDA potting glue in practical applications.

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Detailed explanation of the process flow: the entire process from formula to finished product

The success of TEDA potting glue not only depends on excellent raw material selection, but also requires scientific and rigorous production technology. The following is its complete production process diagram:

1. Formula design and raw material screening

According to customer needs and technical specifications, the engineer team first determines the basic formula, including the type of epoxy resin, the proportion of flame retardant, the type of filler, etc. Each raw material is then subjected to strict quality inspection to ensure that its purity and performance meet the requirements.

2. Mixing and dispersion

The selected raw materials are added to the high-speed mixer in a predetermined proportion, and uniform dispersion is achieved through mechanical shear force. At this stage, an appropriate amount of coupling agent is also required to improve the interface bonding between the filler and the resin.

3. Defoaming treatment

The mixed slurry may have a small amount of bubbles, and if not removed in time, it will affect the performance of the final product. Therefore, TEDA uses vacuum defoaming equipment to process the slurry to ensure that it reaches an ideal leveling state.

4. Packaging and storage

The defoaming potting glue is divided into containers of different specifications and is pasted with detailed label information (such as batch number, validity period, etc.). The finished product must be stored in a constant temperature and humidity environment to prevent deterioration.

5. Quality Inspection

Before leaving the factory, each batch of products must undergo strict quality inspection procedures, including appearance inspection, physical performance testing and performance verification in simulated application environments. Only fully qualified products will be allowed to be put on the market.

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Application cases and customer feedback

TEDA potting glue has been widely used in battery pack manufacturing by many well-known car companies and has received high praise. For example, a leading domestic new energy vehicle manufacturer used TEDA A series potting glue in its new model, and the results showed that the material significantly improved the overall protection capability and service life of the battery pack. In addition, a foreign high-end electric vehicle brand also selected TEDA products in its BMS module packaging, praising it for “not only excellent performance, but also easy to construct.”

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Conclusion: Future prospects and development directions

With the continuous development of the new energy vehicle industry, the requirements for potting glue will become higher and higher. TEDA will continue to increase investment in R&D and explore more new materials and technologiesStrive to provide customers with better products and services. For example, a new generation of potting glues with higher thermal conductivity and lower density may be introduced in the future, or a specialized formula suitable for emerging fields such as solid-state batteries.

In short, TEDA new energy vehicle battery pack potting glue has become a benchmark product in the industry with its excellent UL94 V-0/IP67 dual certification performance. It has demonstrated unparalleled advantages and potential from a technical level or a market perspective. Let us look forward to TEDA bringing more surprises in its future development!

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References

1. ASTM D635-14, Standard Test Method for Rate of Burning and/or Extent and Time of Burning of Plastics in a Horizontal Position.
2. IEC 60529:2018, Degrees of protection provided by enclosures (IP Code).
3. Wang, L., & Zhang, X. (2021). Advances in epoxy-based encapsulants for electronic applications. Journal of Applied Polymer Science, 138(12), 49157.
4. Smith, J. R., & Brown, M. T. (2020). Flame retardancy mechanisms of phosphorus-containing compounds in polymer composites. Polymer Degradation and Stability, 175, 109182.

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