2026 New Energy Vehicle Three-Electric System Potting Glue Guide: How to Balance Lightweight and High Thermal Conductivity Requirements?

Overview of potting technology for three-electric system of new energy vehicles

The "three electric" systems (battery, motor, electronic control) of new energy vehicles are the core components of vehicles, and their thermal management directly affects safety, efficiency and cruising range. As a key material, potting glue has become an indispensable protection technology for the three-electric system by filling the gap between components to provide electrical insulation, mechanical protection and efficient heat dissipation.

Challenges under the lightweight trend in 2026

With the increasing demand for new energy vehicles, the lightweight of the vehicle has become the focus of the industry. According to the plan, the weight reduction target for bicycles in 2026 will reach 35% compared with 2015. The three-electric system accounts for a significant proportion of the vehicle weight, the traditional potting density is high, may increase the burden. Researchers need to prioritize low-density materials, such as lightweight filler composite silicone or polyurethane adhesives, to achieve weight reduction without sacrificing structural strength.

Drivers of high thermal conductivity demand

The high power density of the three-power system generates a lot of heat, and if the heat is not dissipated in time, it is easy to cause thermal runaway. In 2026, with the popularization of fast charging technology and high nickel batteries, the demand for thermal conductivity will further increase. The high-efficiency thermally conductive potting glue can quickly conduct heat to the cooling system, combined with graphene or phase change material filling, the thermal conductivity can reach more than 4 W/m · K, ensuring that the components operate in the optimal temperature range.

How to Balance Lightweight and High Thermal Conductivity

The core lies in material innovation and formula optimization. Low-density and high-thermal-conductivity potting adhesives improve heat transfer efficiency while reducing weight by adding lightweight and efficient fillers (such as expanded graphite). At the same time, silicone-based potting with excellent temperature resistance and elasticity, become the mainstream choice, can adapt to the battery "breathing" effect and support CTP/CTC integrated design, reduce unnecessary components, and further realize the system lightweight.

Recommendations for future selection

In 2026, it is recommended to give priority to multifunctional potting glue: thermal conductivity ≥ 3 W/m K, density <2 g/cm, flame retardant and low volatile properties. Combined with the acceleration trend of domestic substitution, the selection of polyurethane or silicone products with good elasticity and clean production can effectively balance the demand for lightweight and high thermal conductivity, and improve the overall performance and safety of the three-electric system.