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Case Study: Silicone Potting Compound for New Energy EVs and Energy Storage in Southeast Asia

As two-wheel and three-wheel electric vehicles (e-bikes, e-scooters and e-rickshaws) and battery energy storage systems (BESS) continue to expand rapidly across Southeast Asia, manufacturers in the region share one critical challenge: protecting high-voltage battery packs, controllers and power modules from heat, moisture and vibration in hot, humid tropical climates. This case study outlines how a two-component silicone potting compound — HN-8806A/B-2 — helped a Southeast Asian new-energy assembler improve reliability, safety and production efficiency.

Customer Background

The customer is a Southeast Asia-based manufacturer of lithium battery packs for two-wheel and three-wheel electric vehicles, serving markets such as Vietnam, Indonesia, Thailand and the Philippines. Its products operate daily under high-temperature, high-humidity and rainy conditions, where long-term electrical insulation and moisture protection are essential to product safety and warranty performance.

The Challenge

• Battery packs and power modules must withstand operating temperatures from –50°C to +250°C without cracking or softening.
• Constant exposure to tropical humidity, rain and condensation caused moisture ingress and short-circuit risks.
• Vibration from daily road use loosened unprotected components inside the battery enclosure.
• The customer needed a flame-retardant, RoHS-compliant material suitable for automated dispensing lines.

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

HN-8806A/B-2 is a double-component, room-temperature or heat-curing silicone filling glue that cures into a high-performance elastomer. It delivers excellent electrical performance, ageing resistance, wide temperature tolerance, heat conduction, moisture-proofing and deep curing with very low shrinkage. It does not release heat or by-products during curing, does not corrode sealed components and meets RoHS and related environmental requirements.

Key Technical Parameters

Implementation

The compound is supplied as a 100:100 (by weight) two-part system, packed in 25 kg barrels for components A and B. During assembly, components A and B are stirred evenly, weighed in the correct ratio and mixed thoroughly in a clean container, then de-gassed under vacuum to remove bubbles before filling. For the customer’s automatic filling line, both components were evacuated for 5–10 minutes and fed through a static mixer with metering pumps, ensuring an accurate ratio and consistent glue application. The battery packs were cleaned, potted in parts where necessary, and cured at room temperature (1–2 hours) or by heating at 80°C for 0.2 hours.

Results & Benefits

• Superior thermal management: a thermal conductivity of ≥ 0.76 W/m·K efficiently transfers heat away from battery cells and power modules.
• Reliable insulation & moisture protection: volume resistivity of 1.0 * 10¹⁶ Ω·cm and water absorption of only 0.01–0.02% safeguarded packs against tropical humidity.
• Wide temperature range: stable performance from –50°C to +250°C supported both hot charging cycles and cold storage.
• Enhanced safety: UL 94 V-0 flame retardancy and low curing shrinkage reduced fire risk and internal stress.
• Production efficiency: the 1:1 ratio and vacuum de-gassing made the material ideal for automated dispensing, cutting cycle time and rework.

Why It Fits the Southeast Asia Market

Southeast Asia’s tropical climate, rapid e-mobility adoption and growing renewable-energy storage demand make robust encapsulation essential. HN-8806A/B-2’s moisture resistance, heat conduction and flame-retardant properties directly address the region’s harsh operating conditions, while its RoHS compliance supports export requirements across ASEAN markets. The material is proven in sealing power modules, circuit boards, high-voltage transformers, battery packs, fast-charging adapters, LED outdoor power supplies, lamps and lanterns.

Conclusion

By standardising on HN-8806A/B-2 silicone potting compound, the customer strengthened the reliability and safety of its two-wheel and three-wheel EV battery packs and energy storage systems, reduced field failures caused by moisture and heat, and improved production efficiency. For Southeast Asian new-energy manufacturers, high-performance silicone encapsulation is a practical, cost-effective route to more durable and competitive products.