Resin Formulators Thermal Management Solutions Kit

Our custom formulations have solved challenges for a wide range of electric vehicle applications including circuits, charging systems, battery power management, and contactor relays where temperature stability, thermal cycling, electrical insulation, and/or thermal conductivity are required. Applications also include high voltage relay potting, staking of Li-ion battery cells, and encapsulation of motor windings.

An electronic vehicle component manufacturer needed assistance with the completion of their new 1000 amp high voltage contactor unit, intended for use in rapid charging stations. Standard contactor relays are rated for 500 amps, so a new material was required to withstand the temperatures generated during the transmission of higher frequency currents in a high voltage direct contactor relay.

RF 5407 was identified as both the hermetic seal and thermal management interface solution for the contactor relay’s surface. The result was an improved power transmission through the relay, enabling the creation of sustainable devices capable of withstanding the necessary temperatures for rapid EV charging. RF 5407 is now a qualified material for their device.