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Internal insulation and thermal conductivity of PDU (power distribution unit) for new energy vehicles

2025-09-11

Application Scenarios and Pain Points: The PDU is like the "power hub" of an electric vehicle, housing copper busbars, relays, fuses, and other components. These components pose the risk of high-voltage breakdown and arcing. Furthermore, the heat generated by the high current must be effectively managed.

Solution: Potting or encapsulating the high-voltage connectors and copper busbar connections within the PDU enclosure fills all air gaps.

Core Values:

Safety and Insulation: Completely eliminates high-voltage short circuits and arcing caused by condensation and dust, meeting ASIL safety level requirements.

Thermal Management: The thermal conductivity of the gel helps evenly distribute heat from heating components such as relays, preventing localized overheating.

Structural Reinforcement: After curing, the gel securely locks in heavy internal components to withstand the inertial impact of vehicle acceleration and deceleration.

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