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Case Study: Silicone Potting Compound for Two- and Three-Wheel EV Battery Packs in Southeast Asia

Two-wheel and three-wheel electric vehicles — e-bikes, e-scooters, e-rickshaws and light electric motorcycles — are the fastest-growing mobility segment in Southeast Asia. For the battery pack manufacturers powering this boom, protecting high-voltage lithium packs against tropical heat, rain and constant road vibration is a make-or-break engineering challenge. This case study shows how the two-component silicone potting compound HN-8806A/B-2 solved it for a regional EV battery assembler.

Customer Background

The customer assembles lithium-ion battery packs for two-wheel and three-wheel electric vehicles sold across Vietnam, Indonesia, Thailand and the Philippines. Its packs operate in year-round high humidity and frequent rain, with daily charging and discharging cycles that push cells and controllers to high temperatures. Warranty failures caused by moisture ingress and thermal stress were eroding both margin and brand trust.

The Challenge

• Battery packs and controllers had to endure –50°C to +250°C without cracking, softening or losing insulation.
• Tropical humidity, rain and condensation triggered short-circuit risks inside unsealed enclosures.
• Continuous road vibration loosened internal components and solder joints.
• The line required a flame-retardant, RoHS-compliant material compatible with automated dispensing.

The Solution: HN-8806A/B-2 Silicone Potting Compound

HN-8806A/B-2 is a double-component silicone filling glue that cures at room temperature or with heat into a high-performance elastomer. It offers excellent electrical performance, ageing resistance, heat conduction, moisture-proofing and deep curing with very low shrinkage, without releasing heat or by-products. It does not corrode sealed components and meets RoHS and related environmental requirements.

Key Technical Parameters

Implementation

The 100:100 two-part system, packed in 25 kg barrels, was stirred evenly and mixed in the correct ratio in a clean container, then vacuum de-gassed to eliminate bubbles before filling. On the customer’s automated line, components A and B were evacuated for 5–10 minutes and fed through a static mixer with metering pumps for an accurate ratio and uniform application. Packs were cleaned, potted in stages where deep sections required it, and cured at room temperature (1–2 hours) or by heating at 80°C for 0.2 hours.

Results & Benefits

• Better thermal control: thermal conductivity ≥ 0.76 W/m·K transfers heat away from cells and controllers during fast charging.
• Moisture-proof reliability: volume resistivity 1.0 × 10¹⁶ Ω·cm and water absorption 0.01–0.02% blocked tropical humidity.
• Wide temperature range: stable from –50°C to +250°C across hot charging and cool storage.
• Vibration resistance: the cured elastomer locked internal components in place against road shocks.
• Safety & compliance: UL 94 V-0 flame retardancy and RoHS compliance supported regional export demands.

Conclusion

With HN-8806A/B-2, the customer cut moisture- and heat-related field failures, improved pack reliability and safety, and streamlined automated potting. For Southeast Asian e-mobility makers, high-performance silicone encapsulation is a practical route to more durable, competitive two- and three-wheel EV battery packs.