I. Adhesive Scheme for Drive Motor System
New energy drive motors include stators, rotors, housings, end caps, wiring harnesses, cooling water channels, and variable speed transformers, etc. The core requirements are: high temperature resistance, heat conduction, insulation, vibration resistance, waterproof and moisture-proof, oil resistance, and refrigerant resistance.
Stator winding encapsulation
Points: Stator coil gap, iron core insulation encapsulation
Applicable adhesives: Two-component epoxy encapsulation adhesive, thermal conductive polyurethane encapsulation adhesive
Function: Insulation withstand voltage, heat dissipation cooling, buffering vehicle jolts and vibrations, isolating water vapor and oil corrosion of copper wires, suppressing motor operating noise.
Stator core and housing bonding fixation
Points: Outer wall of iron core and motor housing interference fit bonding
Applicable adhesives: High-temperature epoxy structural adhesive, anaerobic holding adhesive (recommended)
Function: High-strength locking, eliminating running gap, transmitting torque, able to withstand 120-180℃ long-term high temperature without delamination.
Motor end cap, housing joint sealing
Points: Front and rear end caps joint surface, cooling water channel cover gap
Applicable adhesives: Silicone flat sealant, MS modified silane sealant
Function: Waterproof, preventing coolant leakage, dustproof, resisting chassis mud and water erosion, having elastic adaptability to cold and hot deformation.
Rotary transformer / temperature sensor fixation
Points: Sensor coil and stator frame bonding
Applicable adhesives: Single-component high-temperature epoxy dispensing, silicone fixing adhesive
Function: Insulation fixation, resisting vibration loosening, not interfering with signal transmission.
Motor wiring harness joint, lead-out wire sealing
Points: Outlet hole, root of terminal waterproof encapsulation
Applicable adhesives: UV dispensing + silicone sealing composite scheme, flexible PU encapsulation adhesive
Function: Prevent water vapor from invading the wiring harness gap and causing short circuits.
II. Adhesive Scheme for Battery PACK System
Covering cells, modules, PACK box, BMS, water cooling plate, wiring harness, etc. The core demands are: heat conduction and flame retardancy, shock and vibration buffering, insulation, low-temperature resistance, lightweight bonding.
Cell and water cooling plate heat conduction filling
Points: Bottom of cell, gap between cell and liquid cooling plate
Applicable adhesives: Two-component heat-conductive polyurethane filling adhesive, heat-conductive silicone pad backing adhesive
Function: Quickly conduct the heat of cell charging and discharging, balance battery temperature difference, avoid risk of thermal runaway.
Cell fixation and buffering bonding
Points: Side wall of cell, cell and plastic bracket adhesion
Applicable adhesives: High-rebound polyurethane foam double-sided adhesive, low-stress silicone bonding adhesive
Function: Absorb vehicle jolts impact, buffer cell thermal expansion and contraction, prevent cell wear and short circuit.
Module metal bracket, end plate structure bonding
Points: Module side plate, fixed bracket and cell support bonding
Applicable adhesives: Epoxy structural adhesive, two-component MS structural adhesive
Function: High-strength load-bearing, meeting vehicle collision safety standards, able to withstand high and low temperature cycling without cracking.
PACK box sealing (upper and lower box bodies, maintenance cover plate)
Points: Aluminum alloy box body joint seam, cover plate sealing groove
Applicable adhesives: Flame-retardant MS modified silane sealant, polyurethane sealant
Function: Whole vehicle IP67 waterproof and dustproof, resisting rain, snow salt corrosion, flame retardant grade V0.
BMS circuit board encapsulation protection
Points: PCB circuit board, sampling wiring harness, low-voltage components
Applicable adhesives: Flame-retardant electronic PU encapsulation adhesive, low-stress organic silicone encapsulation adhesive
Function: Insulation, moisture-proof, resisting vibration, isolating electrolyte volatilization and corroding circuit board.
High-voltage wiring harness, connector sealing fixation
Points: Copper strip insulation covering, connector tail waterproof
Applicable adhesives: UV curing dispensing, heat-conductive silicone sealing adhesive
Function: High-voltage insulation, preventing creepage, water vapor causing high-voltage leakage.
III. Adhesive Scheme for Electronic Control System (VCU/MCU/OBC Vehicle Charger)
The electronic control is the core of the entire vehicle’s control system. It is equipped with numerous components and generates a large amount of heat, demanding strict requirements for insulation, heat conduction, temperature resistance, and moisture protection.
Power IGBT and MOSFETs are thermally conductive and bonded together.
Position: The power chip is bonded to the heat dissipation aluminum substrate.
Application: It quickly discharges the heat generated by the chip to prevent it from being burned by high temperatures.
The electronic control housing is fully sealed.
Position: The upper and lower covers of the aluminum alloy housing are joined.
Application: The adhesive is high-temperature resistant silicone sealant and MS sealant.
Function: It prevents water and dust, and can withstand high temperatures in the engine compartment, oil stains, and antifreeze corrosion.
The PCB is fully encapsulated for protection.
Position: The main control circuit board, capacitors, resistors, and sampling chips are encapsulated as a whole.
Application: The adhesive is low-viscosity flame-retardant polyurethane encapsulation adhesive and flexible silicone encapsulation adhesive.
Function: It insulates and prevents moisture, resists vehicle intense vibration, and reduces the failure of circuit board solder joints.
Low-voltage wiring harness and connectors are fixed with glue.
Position: The root of the plug terminals and the fixing clips for the cable.
Application: In case of wiring harness loosening, it prevents signal interruption caused by vehicle jolting.
The OBC (On-Board Charger) resonant inductor is encapsulated with glue.
Position: The inductor coil and transformer.
Application: It reduces electromagnetic noise, provides insulation and withstands voltage, and avoids high-voltage breakdown.
V. Special adhesive solutions for various on-board sensors
New energy vehicle sensors are distributed throughout the chassis, engine compartment, and battery pack. They are categorized by temperature, pressure, radar, camera, and current sensors:
Battery temperature sensor, motor temperature sensor
Position: The probe fixation and the sealing of the cable tail
Adhesive: High-temperature resistant organic silicone glue and flexible PU sealant
Feature: It does not affect the temperature measurement accuracy, is resistant to high and low temperatures, and is waterproof and insulated.
High-voltage current Hall sensor
Position: The magnetic core coil encapsulation and the shell sealing
Adhesive: Low-stress epoxy encapsulation adhesive
Feature: It insulates and isolates high voltage, resists electromagnetic interference, and prevents shock.
Millimeter-wave radar / parking radar
Position: The sealing of the radar shell and the encapsulation of the internal circuit board
Adhesive: Low dielectric constant organic silicone encapsulation adhesive and MS sealant
Feature: It does not block radar signals, is resistant to weather conditions, and is suitable for outdoor temperature differences.
On-board camera (surround view / autonomous driving camera)
Position: The bonding of the lens bracket, the sealing of the lens and the shell, and the encapsulation of the PCB
Adhesive: Low fogging UV curing adhesive and transparent silicone sealant
Feature: It does not yellow, does not fog, and does not interfere with imaging.
Brake pressure, air conditioning pressure sensor
Position: The bonding of the metal shell and the plastic base, and the encapsulation of the internal chip
Adhesive: Oil-resistant epoxy structural adhesive and single-component epoxy sealant
Feature: It is resistant to brake oil and refrigerant corrosion, and does not leak under high pressure.
VI. Adhesive solutions for vehicle body interior and exterior, and chassis structure
(1) Body structure bonding
Aluminum alloy / steel body sheet assembly, door frame bonding
Adhesive: Two-component epoxy structural adhesive and high-toughness MS structural adhesive
Advantage: It replaces spot welding, reduces weight, improves the torsional stiffness of the body, absorbs collision energy, and prevents corrosion and rust.
Top, rear cover sheet edge sealing
Adhesive: PVC weld seam sealing adhesive and polyurethane sealing adhesive
Function: It fills the gap, prevents rust in the sheet metal gap, and reduces the noise of driving.
Battery pack tray and vehicle chassis bonding
Adhesive: High modulus MS structural adhesive and epoxy shock absorption structural adhesive
Function: It rigidly fixes the battery tray, buffers the impact of the chassis, and prevents corrosion from road mud and water.
(2) Body sealing and waterproofing
Window glass bonding (front windshield, side windows, sunroof)
Adhesive: Single-component polyurethane automotive glass adhesive
Function: Structural bonding + sealing in one, waterproof without leakage, and has collision safety performance.
Door, engine compartment, trunk sealing strips auxiliary sealing
Adhesive: Low-odor butyl sealant and MS modified silane sealant
Function: Eliminate gap noise, waterproof and dustproof, and resist aging and cracking.
(3) Interior and exterior assembly bonding
Assembly bonding of dashboard, central control plastic parts, and door panel interior panels
Adhesives used: low-odor MS glue, flexible PU glue, double-sided foam glue
Function: No whitening, no plastic corrosion, shock absorption and noise reduction, avoiding interior abnormal noise.
Assembly of vehicle roof, carpet, and sound insulation cotton
Adhesives used: environmentally friendly water-based spray glue, polyurethane foam double-sided glue
Characteristics: Low VOC, in line with the interior air quality standards, no glue falling off.
Sealing of lamp housings (headlights, taillights)
Adhesives used: thermoplastic butyl sealant, transparent silicone sealant
Function: Prevent fogging and water ingress of the lamps, resistant to ultraviolet rays and long-term non-yellowing.
(4) Chassis anti-corrosion and shock absorption
Fixation of chassis guard plates and wheel arch inner linings
Adhesives used: impact-resistant polyurethane sealant, foam double-sided glue
Function: Anti-sandstone abrasion, isolation from mud, water, and salt corrosion.
Assembly of shock absorption sleeves and rubber buffer components
Adhesives used: rubber-specific primer + epoxy structural glue
Function: High-strength composite bonding of rubber and metal, resistant to long-term alternating loads without delamination.