1. Headlamp Adhesive Application Points
Reliable Sealing for E-bike Lighting Systems
Electric vehicle headlights usually use PC lenses and ABS/PP housings. During outdoor use, they are exposed to UV sunlight, rain, vibration and temperature changes.
OPUTE 6158 Series Silicone Sealant is designed to provide reliable protection for EV lighting systems.
2. Display Adhesive Application Points
Adhesive Solutions for E-bike Displays
Key applications include lens bonding, housing sealing, wire outlet sealing, speaker sealing, NFC bonding and electronic component fixing.
For different applications, 6269 Series is recommended for housing sealing, NFC bonding and speaker sealing.
6239 Series is recommended for electronic component fixing.
3. Battery Adhesive Application Points
Adhesives are applied throughout the battery pack for housing bonding, component fixing, cell-to-housing bonding, wire harness fixing and battery module potting.
| Adhesive Application Point | Application Location | Adhesive Type | Function |
|---|---|---|---|
| Housing Bonding | Upper Cover – Lower Housing Housing Seam |
RTV Silicone Adhesive | Bonding, Waterproofing |
| PCB Component Fixing | Component Fixing | RTV Silicone Adhesive | Fixing, Vibration Resistance, Flame Retardancy |
| Cell-to-Housing Bonding | Battery Cell / Housing | RTV Silicone Adhesive | Fixing |
| Wire Harness Fixing | Wire Harness | RTV Silicone Adhesive | Preventing Vibration and Cable Pulling |
| Battery Module Potting | Battery Module | Potting Compound | Thermal Conductivity, Sealing |
Battery Pack Housing Bonding
Battery PACK housings are typically made of aluminum alloy, ABS, or PC/ABS.
The adhesive should provide strong bonding, reliable sealing, weather resistance, and compatibility with different materials.
Recommended: 6158 Series Adhesives.
BMS Adhesive & Thermal Management
Thermal Interface Materials for BMS
BMS serves as the control center of the battery PACK, responsible for battery monitoring, protection and communication.
Adhesives should provide reliable bonding, electrical insulation and thermal management under vibration, shock and temperature fluctuations.
| Application Location | Thermal Interface Material | Key Requirements | Function |
|---|---|---|---|
| MOSFET Power Transistors | Thermal Grease | Electrical Insulation, Low Thermal Resistance | Efficient Heat Dissipation |
| Cell Balancing Resistor Area | Thermal Pad | Compressible, Tear Resistant | Gap Filling, Heat Spreading |
| MCU / AFE Chips | Thermal Gel / Pad | Low Stress, Low Volatility, Non-Contaminating | Stable Temperature Control |
| High-Current Shunt Resistor | Thermal Pad | Long-Term Thermal Stability, High Thermal Conductivity | Prevention of Thermal Drift |
Battery Cell Fixing & Bonding
Cell-to-housing bonding is essential for securing battery modules in the PACK.
The adhesive should offer high bonding strength, fatigue resistance, temperature resistance and thermal conductivity.
Recommended: 6239 and 6158 Series Adhesives.
Wire Harness Fixing
Wire harnesses in battery PACKs require secure fixation to prevent vibration and abrasion.
The adhesive should offer strong bonding, flexibility, insulation and fast curing.
Recommended: 6239 Series and 319 Two-Component Adhesives.
Thermally Conductive Potting Compounds
Thermally conductive potting compounds provide excellent gap filling, heat transfer, sealing and vibration protection.
They are suitable for battery PACKs requiring efficient thermal management, especially energy storage systems.
Recommended: 916 Series Thermally Conductive Potting Compounds.
4. Controller Adhesive Application Points
The controller integrates PCB, power components, thermal management systems, wire harnesses, connectors and sealing structures.
| Adhesive Application Point | Application Location | Adhesive Type | Function |
|---|---|---|---|
| Housing Sealing | Upper Cover ↔ Lower Housing Housing Seam Around Screws |
RTV Silicone | Flame Retardancy, Bonding, Waterproofing |
| PCB Component Fixing | Large Capacitors, Transformers, Inductors and Other Components | RTV Silicone | Fixing, Vibration Resistance, Flame Retardancy, Transportation Damage Protection |
| Wire Harness Fixing | Wire Harness | RTV Silicone | Preventing Vibration, Pulling and Abrasion |
| PCB-to-Housing Interface | PCB / Housing | Thermal Grease | Thermal Conductivity, Fixation |
| Wire Harness-to-Housing Fixing | Cable Outlet, Waterproof Connector | RTV Silicone | Waterproofing, Anti-loosening |
| Heat Sink | Heat Sink | Thermal Grease / Thermal Pad / Thermal Gel | Thermal Conductivity and Heat Dissipation |
| Busbar Fixing / Insulation | Busbar | Dispensing / Potting | Fixing and Insulation |
| Internal Controller Potting | Internal Controller | Potting Compound | Thermal Conductivity, Electrical Insulation, Shock Absorption, Waterproofing |
Adhesive & Thermal Management Solutions
Controller applications include enclosure sealing, PCB component fixing, wire harness fixing, heat sink thermal management and internal potting.
The material selection depends on requirements such as waterproofing, vibration resistance, insulation, thermal conductivity and shock absorption.
Controller Material Solutions
916 1:1 Thermally Conductive Potting Compound
Applied inside the brake for encapsulation.
7116-1 & 6158DT-1
Enclosure sealing. 6158DT-1 is the flame-retardant grade.
6158DT-1 & 6239
Fixing and securing components on the PCB.
6516-7 & 6516-7R
Applied to wiring terminals for sealing and insulation.
TG10 & TG20
Thermal interface between the aluminum substrate and housing.
5. Motor Shaft Adhesive Application Points
Shaft Hole & End Cover Bonding
Motor shaft adhesive applications include shaft hole bonding and end cover bonding.
7219 Series provides easy use and long curing time. 6158-12 Series provides fast curing and is suitable for automated production, with air-tightness testing within 30 minutes.
For end cover bonding, 5117 Blue provides easy identification and simple application, while 6158-13 Series provides fast curing with strong adhesion.
E-bike Adhesive & Thermal Management Solutions
OPUTE provides silicone adhesives, sealants, thermal interface materials and potting compounds for different e-bike application requirements.
Contact OPUTE