Blue EV Charger Power Module Control Board Gel Potting

Product Overview:

Hong Ye HY-9405 is a premium two-component addition-cure platinum catalyzed blue jelly gel specifically engineered for weatherproof gel potting of power modules, control boards and charging-gun electronics in outdoor AC and DC electric vehicle chargers. With a buttery soft consistency measured at a penetration of 170 plus or minus 30 (0.1mm) and a durably tacky surface, HY-9405 delivers reliable long-life sealing and protection that outlasts conventional gaskets, foams and caulks by a wide margin. The product is mixed 1:1 by weight, self-levels after pouring, cures at room temperature within 4 to 6 hours, and requires no vacuum degassing, making it a straightforward high-performance gel to deploy on production lines worldwide. As a low viscosity fast flow grade, this variant pours easily into narrow channels and complex cavities, levels quickly with minimal bubbles, and is optimized for automated meter-mix dispensing on high-speed lines. It is designed for the internal power and control electronics of DC fast chargers, AC destination chargers and charging guns installed outdoors or in semi-exposed parking areas, where assemblies must achieve long-term waterproofing against rain and humidity while tolerating load-cycle heating and cold-soak conditions. (EN) Backed by Hong Ye’s nearly 20 years of silicone manufacturing expertise and supplied to customers in over 60 countries, HY-9405 combines the performance of premium imported gels with the cost efficiency, short lead time and responsive technical support of a Chinese manufacturer. Whether you are running a first sample trial or ramping to full production, Hong Ye delivers consistent batch-to-batch quality, comprehensive documentation and application engineering support from first sample through full production.

Key Features:

• Low viscosity fast flow formulation fills narrow gaps and intricate cavities quickly, self-levels with minimal bubbles and suits automated dispensing.

• Excellent electrical insulation with dielectric strength above 20 kV/mm

• Repairable and reworkable: old gel can be topped up with fresh gel without full removal

• No VOC emissions during or after cure, suitable for enclosed cleanroom and medical environments

• Can be heat-cured at 60-80C for 30-60 minutes to shorten demolding time in mass production

• Resistant to ozone, UV, moisture, salt spray and common cleanroom cleaning agents

• 1:1 mix ratio by weight, easy to meter with manual or automated dispensing equipment

• Compatible with automated meter-mix dispensing equipment for high-volume production lines

• 12 month shelf life when sealed and stored below 25C in dry ventilated conditions

• Third-party test reports including RoHS, REACH, FDA and LFGB available on request

• Self-leveling after pouring, no vacuum degassing required, saving process time and equipment

• Recommended model: HY-9405 - Blue medium tack electronic potting jelly gel

Technical Parameters:

Detailed Application Scenarios:

EV charging infrastructure places power modules, metering and control boards, contactor drivers and charging-gun authentication electronics in outdoor cabinets and connectors exposed to rain, humidity, road spray, dust and wide temperature swings. HY-9405 is potted around these assemblies to deliver IP-rated moisture sealing and vibration damping while staying soft enough to avoid stressing large capacitors, inductors and solder joints through thermal cycling. The low-modulus gel also absorbs the mechanical shock of connector mating and cabinet door handling.

Because chargers are serviced in the field over many years, the reworkable gel lets technicians expose and replace a failed board and re-pour the local area instead of discarding a whole power cabinet, a major lifecycle cost advantage over epoxy. The gel self-levels into finned heat-sink housings and crowded boards without vacuum equipment and cures overnight at room temperature or in under an hour with heat for line production. It resists UV-degradation-related seal failure in sheltered cabinet interiors and tolerates operating temperatures to 200C near heat-generating modules. Hong Ye provides outdoor-appropriate documentation and flame-retardant options for charger OEMs.

Application & Operating Instructions:

Step 1 Surface preparation: Clean the housing or PCB with a dry lint-free cloth. Remove oil, moisture, flux residue and dust. For reliable adhesion, wipe with isopropyl alcohol and allow to fully dry.

Step 2 Component B preparation: Before each use, stir component B thoroughly for at least 2 minutes. Pigment and catalyst can settle during storage; incomplete stirring causes color variation and soft or uncured spots.

Step 3 Weighing and mixing: Weigh A and B at exactly 1:1 by weight using a calibrated scale. Pour into a clean container and stir slowly for 3 to 5 minutes, scraping the sides and bottom. Avoid fast stirring which introduces bubbles.

Step 4 Potting: Pour the mixed gel slowly into the housing, allowing it to flow around components and self-level. Do not pour from a height to avoid air entrapment. For deep or complex cavities, pot in layers.

Step 5 Curing: Allow 4 to 6 hours at 25C before handling; full properties develop after 24 hours. For mass production, heat-cure at 60-80C for 30-60 minutes. No vacuum degassing is required.

Step 6 Contamination prevention: Use polyethylene, nylon or nitrile gloves. Never use natural rubber latex gloves. Avoid contact with sulfur-containing materials, amines, phosphorus compounds, tin-cured silicone and PVC, as these inhibit the platinum catalyst.

Model Selection Guide:

The HY-94 series offers three standard grades to cover the full range of jelly gel applications, and custom formulations are available for volume orders:

HY-9400 (Blue, High Tack, Penetration 200): The soft, high-tack grade, designed for HEPA/ULPA filter gel seals in cleanrooms, biosafety cabinets, pharmaceutical GMP facilities, hospital operating rooms, semiconductor fabs, lithium battery dry rooms and data centers. Choose this model when strong self-healing and conformability to knife-edge channels are key requirements.

HY-9405 (Blue, Medium Tack, Penetration 170): The balanced all-rounder for instrument meter sealing, electronic encapsulation and outdoor waterproofing. Typical applications include smart water/gas/electric meters, automotive ECUs and sensors, solar PV junction boxes, LED modules, underwater lights, battery management systems and pressure sensors. Choose this model when you need a combination of flowability, structural support, vibration damping and repairability.

HY-9409 (Transparent, Low Tack, Penetration 150): The premium skin-contact grade for intimate apparel and medical products. Typical applications include silicone bra pads, push-up inserts, breast prostheses, nipple covers, bridal and swimwear gel pads, orthopedic insoles, baby products and surgical positioning pads. Choose this model when clarity, dry skin feel, anti-yellowing and body-safe materials are required.

If your project requires a different penetration, color, cure speed or special certification (FDA, LFGB, UL94), contact Hong Ye technical support for a custom formulation. Custom MOQ starts from 20kg and typical lead time is 7 to 10 working days.

Recommended Application: EV Charger Power Module Control Board Gel Potting

Packaging:

Standard packaging options include 1kg trial kits (500g A + 500g B), 5kg kits, 20kg pails, 25kg pails and 200kg drums. Components A and B are supplied in separate containers within each kit. Custom packaging and private labeling are available for orders above 200kg. All kits are clearly labeled with batch number, manufacture date, expiry date and safety information.

Precautions:

Use polyethylene, nylon or nitrile gloves; never use natural rubber latex gloves. Avoid contact with sulfur-containing materials, amines, phosphorus compounds, tin-cured silicone and PVC, as these inhibit the platinum catalyst and prevent cure. Mix A and B at exactly 1:1 ratio by weight using a calibrated scale. Stir thoroughly for 3-5 minutes, scraping container walls and bottom. Do not exceed 100C during heat curing. Ensure good ventilation during operation.

Storage:

Store sealed containers in a dry, ventilated area below 25C, away from direct sunlight, sulfur-containing materials, amines, food and strong chemicals. Shelf life is 12 months from manufacture date. Reseal unused material immediately after dispensing. Refrigerated storage at 5-15C can extend shelf life; allow material to return to room temperature before opening to prevent condensation.

FAQ:

Q: How long does the gel take to cure and can I speed it up?

A: At 25C the gel reaches touch-dry in 4 to 6 hours and full properties after 24 hours. For mass production, heat-curing at 60 to 80C reduces the cycle to 30 to 60 minutes. Do not exceed 100C. Low temperatures below 15C will significantly slow the cure.

Q: Can potted electronics be repaired or reworked later?

A: Yes. Unlike hard epoxy, the soft jelly gel can be cut or peeled back to access components for repair, and fresh gel can be poured back over the area to restore protection. This repairability is a major advantage for serviceable outdoor and industrial electronics.

Q: What waterproof and insulation protection does it provide?

A: The cured gel provides continuous moisture and salt-spray protection with dielectric strength above 20 kV/mm and volume resistivity above 10^14 ohm-cm. Properly potted assemblies reliably meet IP65/IP67 requirements in outdoor environments.

Q: Will the soft gel stress sensitive components?

A: No. The low-modulus jelly gel cures into a soft mass that absorbs vibration and thermal expansion without exerting stress on fragile components, wires or solder joints, unlike rigid epoxy that can crack parts under temperature cycling.