EV Charging Industry – Silicone Product Application Solutions

作者 Gubang | Jul 24, 2026

Scope: DC fast chargers, AC chargers, ultra-fast chargers, charging modules, connectors and cables, and integrated storage-and-charging systems

1. EV Charging Industry Overview

1.1 EV Charging Industry Development Trends

The global EV charging market is growing rapidly as new-energy vehicle penetration accelerates. In 2026 China's charging infrastructure market exceeded RMB 100 billion, with an installed base of more than 12 million units and a steadily rising share of DC fast chargers. As 800V high-voltage vehicle platforms reach volume production, ultra-fast chargers (≥350kW) are being deployed at pace, imposing stringent demands on the power density and thermal management of charging modules.

As all-weather outdoor equipment, charging stations must withstand high temperature, high humidity, salt mist and wide temperature swings. Electronic silicone materials play an irreplaceable role in power module heat dissipation, connector sealing, control board protection and potting insulation. Standards such as GB/T 18487 and NB/T 33008 set explicit requirements for ingress protection, dielectric withstand voltage and flame ratings of charging equipment.

1.2 Core Value of Electronic Silicones in EV Charging Equipment

Value Dimension

Application

Benefit

Heat Dissipation

IGBT/SiC heat dissipation in charging modules, DC/DC transformer cooling

Reduces temperature rise by 20~40℃ and extends module life by 50%

Insulation Protection

High-voltage busbar insulation potting, terminal insulation

Withstand voltage 3~5kV, compliant with GB/T safety requirements

Waterproof Sealing

Connector head sealing, enclosure sealing, display sealing

IP67/IP68 with a 10-year outdoor service life

Flame Safety

Power module potting, internal connector encapsulation

UL94 V-0, passes the 850℃ glow wire test

Cushioning Protection

Structural cushioning of the connector head, cable strain relief

Drop-resistant IP67, 100,000+ mating cycles

Corrosion Protection

1.3 Charger Architecture and Silicone Requirement Mapping

Charging Module (core assembly): IGBT/SiC (TC series thermal grease) → transformers and inductors (PT series potting compound) → PCBA (PC series conformal coating)Charging Connector and Cable: connector head sealing (SS series) → terminal insulation (IC series) → cable strain relief (structural bonding)Enclosure: main control board protection (PC200) → enclosure sealing (MT-704A) → display sealing (SS clear grade)Storage / PV Ancillaries: battery pack potting (PT series) → PV junction box (sealing)

2. Product Portfolio Overview

2.1 Core Product Series

Product Series

Product Name

Typical Model

Key Features

High Thermal Conductivity Grease

Charging Module Thermal Grease

MT-3202/3203/3206

Thermal conductivity 2.0~6.0 W/m·K, low oil bleed, long service life

Thermally Conductive Potting Compound

Power Module Potting Compound

MT-2804/2807

Thermal conductivity 0.8~1.5 W/m·K, UL94 V-0 flame retardant, high-temperature resistant

Insulating Potting Compound

High-Voltage Insulating Potting Compound

MT-2806

Dielectric strength >30 kV/mm, enhanced creepage distance

Silicone Sealant

Outdoor Sealant

MT-704A

IP68 waterproof, 10-year UV and salt spray resistance

2.2 Technical Advantages

6.0 W/m·K ultra-high conductivity grease: handles heat flux above 1000 W/m² in ultra-fast charging modules

30 kV/mm insulating potting: meets insulation safety requirements for 1500V high-voltage systems

IP68 sealing with 10-year life: validated by 3000h QUV and 1000h salt spray testing

Full UL94 V-0 coverage: UL Yellow Cards for potting compounds, conformal coatings and sealants

Self-cleaning formulation: hydrophobic, self-cleaning sealant surface reduces outdoor dust build-up

3. Charging Module Thermal Management Solutions

Figure 3-1 DC Fast Charging Module Cooling and Connector Sealing Solution

Figure 3-2 Liquid Cooling and Charger Power Levels

3.1 Charging Module Thermal Management Overview

The charging module is the heart of a DC charger, and the cooling efficiency of its internal IGBT/SiC power devices directly determines the charger's rated power, reliability and service life. Mainstream charging module power levels today:

Module Type

Power

Heat Flux

Cooling Method

Silicone Requirement

Constant-power module (mainstream)

15~30kW

5~8 W/cm²

Air / liquid cooling

MT-3203 thermal grease

SiC ultra-fast charging module

40~60kW

8~12 W/cm²

Primarily liquid cooling

MT-3206 ultra-high conductivity grease

Energy storage DC/DC module

50~100kW

6~10 W/cm²

Liquid cooling

MT-3206 + MT-2806 potting

3.2 IGBT/SiC Power Device Thermal Solution

Application point: between the back of the IGBT/SiC module and the cold plate or heat sink baseRecommended product: MT-3206 ultra-high thermal conductivity grease (6.0 W/m·K)

Parameter

MT-3206

Industry-standard MT-3203

Improvement

Thermal Conductivity

6.0 W/m·K

3.0~5.0

+20~100%

Thermal Resistance (@50psi)

0.025 ℃·cm²/W

0.04~0.06

-40~60%

Oil Bleed (200℃/24h)

<0.2%

<0.5%

Lower

Continuous Operating Temperature

-55℃~200℃

Equivalent

Dielectric Strength

>12 kV/mm

>10 kV/mm

Higher

Application Process:

Clean the baseplate and module underside (plasma cleaning recommended)
Apply by stencil printing or automated dispensing, controlling thickness at 80~120μm
Mount the module → secure with screws (recommended torque 0.4~0.6 N·m)
Thermal resistance verification: ΔT ≤5℃ between module and heat sink

3.3 Transformer and Inductor Potting Solution

Application points: high-frequency transformers, PFC inductors and LLC resonant inductors inside the charging moduleRecommended product: MT-2806 high thermal conductivity potting compound

Parameter

MT-2806

Thermal Conductivity

1.2 W/m·K

Flame Retardancy

UL94 V-0

Dielectric Strength

22 kV/mm

Viscosity

3000 cP

Cure Schedule

80℃ × 1h or 25℃ × 24h

Temperature Resistance

-55℃~180℃

3.4 Cold Plate Thermal Interface Solution

4. Charging Connector and Cable Solutions

4.1 Charging Connector Head Sealing Solution

Application points: the connector-to-charger interface and internal terminal insulation of the connector headRecommended products: MT-704A silicone sealant + MT-2806 insulating potting compound

Sealing Location

4.2 Charging Cable Strain Relief Solution

4.3 High-Temperature Protection for Connector Terminals

Application point: insulation isolation of power terminals inside DC charging connectorsRecommended product: MT-2806 high-voltage insulating potting compoundKey requirements:

Dielectric strength ≥30 kV/mm
200℃ high-temperature resistance (high-current terminal heating)
Tracking resistance CTI ≥600V
UL94 V-0 flame retardancy

5. Outdoor Protection and Enclosure Sealing Solutions

5.1 Charger Enclosure Sealing Solution

Application points: front and rear door mating surfaces, cable entry holes and heat sink interfaces

Sealing Location

5.2 Liquid Cooling Interface Sealing Solution

Application points: quick couplings of the liquid cooling loop and coolant pipe interfacesRecommended product: MT-704A (coolant-resistant grade)Key requirements:

Long-term resistance to coolant (glycol/water mixture) at 85℃
Pressure resistance ≥1 MPa
Sealing life ≥8 years
Retains elasticity down to -40℃

5.3 Outdoor Environmental Qualification

Outdoor charging environments require silicone materials to pass the following qualification tests:

UV resistance: 3000h QUV (UVA-340) with no cracking, chalking or discoloration
Salt spray resistance: 1000h neutral salt spray with no corrosion
Temperature resistance: 100 cycles from -40℃ to 85℃
Mold resistance: ASTM G21, rating 0 after 28 days
Flame retardancy: UL94 V-0 / GB/T 5169 850℃ glow wire

6. Integrated Storage-and-Charging System Solutions

6.1 Battery Pack Potting Solution

Application point: internal heat dissipation and protection of lithium-ion storage battery modulesRecommended product: MT-2806 thermally conductive flame-retardant potting compound

Parameter

MT-2807

Thermal Conductivity

1.5 W/m·K

Flame Retardancy

UL94 V-0

Dielectric Strength

20 kV/mm

Flame retardancy combined with heat dissipation

Balances cell-to-cell temperature differential to <5℃

6.2 PV MPPT Module Cooling

Recommended product: MT-3203 high thermal conductivity greaseApplication points:

Power transistor cooling in MPPT boost modules
DC/DC converter cooling
PV input junction box sealing

6.3 Storage BMS Protection

7. Wireless Charging and PV-Storage-Charging Solutions

7.1 Wireless Charging Coil Potting Solution

Recommended product: MT-2804 (low dielectric loss grade)Coil protection requirements for wireless charging systems:

Low dielectric loss: Df ≤0.001 @100kHz
High thermal conductivity: ≥0.8 W/m·K
Outdoor durability: IP67 + UV resistance
No magnetic interference

7.2 Integrated PV-Storage-Charging System Cooling

Recommended products:

PV MPPT → MT-3203 (3.0 W/m·K)
Battery pack potting → MT-2807 (1.5 W/m·K)
Charging module → MT-3206 (6.0 W/m·K)
Enclosure sealing → MT-704A

7.3 Megawatt Charging System (MCS) Solution

Special requirements of megawatt-class charging (Megawatt Charging System):

1500V high-voltage insulation system
Heat flux >15 W/cm² → MT-3206
IP69K high-pressure jet washing
Liquid cooling coupling sealing life of 10 years or more

8. Selection Guide and Technical Data Comparison

8.1 Quick Selection Matrix

Application Scenario

Primary Requirement

8.2 Thermal Silicone Selection Guide

Thermal selection hierarchy for EV chargers: SiC/IGBT die level (>10 W/cm²) → MT-3206 thermal grease (6.0 W/m·K) IGBT / diode module level (5~10 W/cm²) → MT-3203 thermal grease (3.0 W/m·K) Transformer / inductor level (3~5 W/cm²) → MT-2806 potting compound (1.2 W/m·K)

9. Competitive Advantages

9.1 Technical Advantages

6.0 W/m·K ultra-high conductivity grease: developed specifically for ultra-fast charging modules and silicon carbide device cooling

30 kV/mm insulating potting: meets insulation safety requirements for 1500V high-voltage systems

Self-cleaning sealant: superhydrophobic surface (contact angle >110°) reduces outdoor dust build-up

Low dielectric dissipation: Df <0.001, ideal for wireless charging and communication modules

Full-range UL Yellow Cards: UL certification available for potting compounds, conformal coatings and sealants

9.2 Quality Advantages

Quality Dimension

Industry Standard

Maxtor Level

Batch Cpk

≥1.33

≥1.67

Thermal Conductivity Tolerance

±0.2 W/m·K

±0.15

Viscosity Tolerance

±20%

±10%

Flame Certification

V-0 (self-declared)

V-0 (UL Yellow Card)

Insulation Stability

85℃/85%RH 1000h

>95% performance retention after 5000h

9.3 Service Advantages

Thermal simulation support: joint thermal simulation of your charging modules
Samples shipped within 24h: trial samples matched to your power devices
On-site production support: engineers on site to guide potting and coating processes during the first production run
Compliance documentation: complete UL / RoHS / REACH / MSDS document packages
Joint development: custom formulations for next-generation ultra-fast charging and PV-storage-charging systems

10. Representative Case Studies

Case 1: Thermal Solution for a 360kW High-Power DC Fast Charging Module

Customer background:

A leading charging equipment manufacturer, charging modules for a 360kW cluster charging system

Requirement:

IGBT cooling in a 30kW charging module; the incumbent grease had high thermal resistance, forcing module derating

Solution:

MT-3203 (3.0 W/m·K) replaced the incumbent product, with optimized coating uniformity

Results:

IGBT junction temperature reduced by 25℃; modules deliver full rated power
Module fault derating rate reduced from 12% to 1.5%
Annual shipments exceed 500,000 units

Case 2: IP67 Sealing Life Improvement for Charging Connectors

Customer background:

A charging connector and cable manufacturer exporting to the European market

Requirement:

Connector head sealing had to meet IP67, 100,000 mating cycles and 3000h UV resistance

Solution:

MT-704A sealant plus SI-CP-LSR cushioning pads in the connector head

Results:

Passed IP67 and IK10 testing
IP67 sealing maintained after 100,000 mating cycles
TÜV certification obtained
Annual supply of 300,000 connectors

Case 3: SiC Ultra-Fast Charging Module Upgrade

Customer background:

A next-generation ultra-fast charging platform, 60kW SiC charging modules

Requirement:

SiC module heat flux exceeded 12 W/cm², requiring thermal conductivity above 5 W/m·K

Solution:

MT-3206 (6.0 W/m·K) combined with cold plate interface optimization

Results:

SiC module junction temperature below 85℃ at full power in a 50℃ ambient
Module power density increased by 40%
Passed AEC-Q automotive-grade reliability qualification

Case 4: Corrosion Protection Upgrade for Coastal Charging Stations

Customer background:

A coastal-city charging network operator facing a 20% enclosure corrosion complaint rate

Requirement:

Raise internal and external protection levels; no corrosion after 500h salt spray

Solution:

MT-704A enclosure sealing + PC200 conformal coating on control boards + MT-2806 terminal insulation

Results:

Corrosion complaint rate reduced from 20% to 0.5%
Warranty period extended from 2 years to 5 years
Operation and maintenance costs reduced by 60%

11. Technical Service System

11.1 Pre-Sales Service

Service Item

Description

Response Time

Technical consultation

Product selection + solution design + thermal simulation

Within 2 hours

Free samples

Trial samples matched to your modules or connectors

Within 24 hours

Application testing

Trial builds and testing on charger modules

3 business days

Process package

Application process package + SOP

5 business days

On-site visit

Technical exchange + production line review

Within 1 week

11.2 Service During Delivery

On-site support for the first run: engineers guide the production ramp-up on site
Operator training: SOP preparation + on-site training
Equipment integration: parameters for potting, coating and dispensing equipment
Compliance documentation: complete UL / GB/T 18487 / TÜV document package

12.3 After-Sales Service

Quarterly reviews: quarterly quality visits + joint assessments
Batch traceability: retained samples kept for 5 years + full process records
Failure analysis: 24h response + 8D corrective action report
Technology upgrades: advance development of formulations for next-generation ultra-fast charging and PV-storage-charging systems

Committed to delivering complete thermal, insulation, sealing and protection solutions for the EV charging industry

EV Charging Industry – Silicone Product Application Solutions

Table of Contents

1. EV Charging Industry Overview

1.1 EV Charging Industry Development Trends

1.2 Core Value of Electronic Silicones in EV Charging Equipment

1.3 Charger Architecture and Silicone Requirement Mapping

2. Product Portfolio Overview

2.1 Core Product Series

2.2 Technical Advantages

3. Charging Module Thermal Management Solutions

3.1 Charging Module Thermal Management Overview

3.2 IGBT/SiC Power Device Thermal Solution

3.3 Transformer and Inductor Potting Solution

3.4 Cold Plate Thermal Interface Solution

4. Charging Connector and Cable Solutions

4.1 Charging Connector Head Sealing Solution

4.2 Charging Cable Strain Relief Solution

4.3 High-Temperature Protection for Connector Terminals

5. Outdoor Protection and Enclosure Sealing Solutions

5.1 Charger Enclosure Sealing Solution

5.2 Liquid Cooling Interface Sealing Solution

5.3 Outdoor Environmental Qualification

6. Integrated Storage-and-Charging System Solutions

6.1 Battery Pack Potting Solution

1.5 W/m·K

6.2 PV MPPT Module Cooling

6.3 Storage BMS Protection

7. Wireless Charging and PV-Storage-Charging Solutions

7.1 Wireless Charging Coil Potting Solution

7.2 Integrated PV-Storage-Charging System Cooling

7.3 Megawatt Charging System (MCS) Solution

8. Selection Guide and Technical Data Comparison

8.1 Quick Selection Matrix

8.2 Thermal Silicone Selection Guide

9. Competitive Advantages

9.1 Technical Advantages

9.2 Quality Advantages

9.3 Service Advantages

10. Representative Case Studies

11. Technical Service System

11.1 Pre-Sales Service

11.2 Service During Delivery

12.3 After-Sales Service