Power electronics used in electric vehicles (EVs) and industrial systems are increasingly exposed to sustained heat, humidity, vibration, and electrical stress. Assemblies such as traction inverters, onboard chargers, dc-dc converters, battery management systems, motor controls, and industrial power modules require encapsulation materials that maintain electrical insulation and mechanical stability under demanding operating conditions.
Henkel has introduced Loctite STYCAST US 8000 A/B, a two-component polyurethane potting compound developed for electronic protection in industrial and power electronics applications. Applications include EV power electronics modules, battery management units, HVAC control modules, inverters, power supplies, and industrial sensors.
The material features ultra-low ionic content (<20 ppm), intended to reduce corrosion and mitigate silver migration in high-humidity environments, a common contributor to leakage currents and insulation failure. It carries a UL 746 RTI rating of 140°C and UL 94 V-0 flammability certification, supporting thermal endurance and safety compliance requirements.
Electrically, the compound provides a dielectric strength of 24 kV/mm and surface insulation resistance above 10⁸ Ω after 500 hours at 85°C/85% RH, indicating stability under prolonged environmental stress conditions aligned with automotive and industrial qualification standards.
With a mixed viscosity of 3,800–5,800 mPa·s and a 4:1 mixing ratio, the material supports controlled dispensing and flow into narrow gaps and complex geometries, enabling void-free encapsulation in high-density assemblies. It can cure at room temperature or under accelerated thermal schedules, providing flexibility for high-volume manufacturing.
Mechanically, the compound offers a Shore A hardness of 89, tensile strength of 9 MPa, and 87% elongation, allowing it to accommodate vibration and thermal expansion in power electronics assemblies subject to dynamic loading.
As EV platforms move toward higher voltages and greater power density, materials that combine low ionic contamination, strong dielectric performance, and mechanical durability are becoming increasingly important to long-term system reliability.
Filed Under: Adhesives, Technology News