From 80μm to 15μm: Core Technical Solution for Polyurethane Potting Compound Grinding and Dispersion
With the rapid development of the new energy vehicle industry, the performance requirements for encapsulation materials used in core components such as power batteries, BMS (Battery Management Systems), and motor controllers continue to rise. Polyurethane potting compound, with its excellent elasticity, impact resistance, low-temperature resistance, and thermally conductive insulating properties, has become one of the mainstream materials for electronic encapsulation in new energy vehicles. Its market penetration rate has been increasing year by year. In 2025, the penetration rate of polyurethane in domestic BMS potting compounds reached 61.3%, and it is expected to exceed 68% in 2026.
In key components such as power battery modules, on-board chargers, and DC-DC converters, polyurethane potting compound not only needs to fulfill basic functions of thermal conductivity, shock resistance, and insulation, but must also withstand long-term stability challenges under complex operating conditions. However, traditional polyurethane potting compound production commonly suffers from issues such as uneven filler dispersion and excessively large particle sizes, which directly affect the material's thermal conductivity efficiency, mechanical properties, and long-term reliability, becoming a key bottleneck restricting product performance upgrades.
Problem Challenges
Through communication with customers, we have identified that the current production of polyurethane potting compound mainly faces the following core challenges:
- Uneven filler dispersion and excessive particle size: Thermally conductive fillers (such as alumina and boron nitride) tend to agglomerate, with initial particle sizes generally exceeding 80μm. This fails to meet the requirements for constructing high-efficiency thermal conduction pathways in new energy vehicles, leading to increased local thermal resistance and reduced heat dissipation efficiency.
- High risk of solid-liquid separation: Traditional grinding processes can easily cause separation between the polyurethane resin and inorganic fillers, resulting in sedimentation and agglomeration, which disrupts the colloidal stability and affects product consistency.
- Low process efficiency: Some equipment requires multiple grinding passes to reduce particle size, resulting in long production cycles and high energy consumption, making it difficult to adapt to customers' large-scale production needs.
- Severe performance impact: Uneven dispersion directly leads to reduced thermal conductivity and insufficient insulation strength of the compound. Long-term use may result in localized overheating, cracking, insulation failure, and other issues, compromising product safety and service life.
Solution
To address the above pain points, we have launched a three-stage dispersion process solution centered around the ZYTR-80E Plus three-roll mill. Through precise roll gap control and high-efficiency shear grinding, it achieves uniform dispersion and particle size optimization of polyurethane potting compound:
- Equipment selection:The ZYTR-80E Plus three-roll mill features high wear resistance and corrosion resistance, providing stable shear force that is well-suited for high-viscosity polyurethane systems, effectively avoiding solid-liquid separation issues.
- Full-process quality control:Fineness testing using a scraper fineness gauge is performed before and after grinding to ensure that the product fineness consistently meets standards. Meanwhile, equipment operating parameters are optimized to achieve uniform discharge without leakage, ensuring production continuity.
- Efficiency improvement solution:By optimizing roll gap parameters, the fineness can be reduced to the target value in just three grinding passes, significantly shortening the production cycle and reducing the customer's overall production costs.
Experimental Process
Customer: A new materials company in Huzhou
Test material: Two-component polyether-type polyurethane potting compound
Test equipment: ZYTR-80E Plus three-roll mill + scraper fineness gauge
Test objective: To achieve more uniform dispersion and reduce particle size of the material through three-roll mill grinding
Test procedure:
1.Initial inspection: Scraper fineness gauge showed 80μm
2.Three-stage dispersion process:
The ZYTR-80E Plus three-roll mill was used to disperse and grind the slurry through a three-stage dispersion process to ensure particle size reduction.
- Coarse mixing stage: Roll gap 80-40μm
- Primary fine grinding: Roll gap 30-15μm
- Secondary fine grinding: Roll gap 20-10μm
During the three-roll mill operation, discharge was uniform with no leakage, as shown in the figure below:
Grinding effect of polyurethane Component B
3.Output inspection: Scraper fineness gauge showed 15μm
Results Analysis
Using ZYE Technology's ZYTR-80E Plus three-roll mill, comparison of the scraper fineness gauge results shows:
1、Fineness breakthrough: Reduced from an initial 80μm to 15μm, a reduction of 81%.
2、Process advantages:
- Compared to other three-roll mill manufacturers, ZYE's three-roll mill did not exhibit solid-liquid separation, significantly improving the colloidal stability.
- Fineness can be reduced to the minimum in just three passes, significantly shortening the production cycle, improving production efficiency, and reducing the customer's production costs.
- Uniform discharge with no leakage and no waste, suitable for large-scale production needs.
Application Prospects
With the continued growth of the new energy vehicle industry, it is projected that by 2030, China's new energy vehicle sales will exceed 15 million units, corresponding to an annual demand for potting compounds exceeding 28,000 tons for core components such as BMS, OBC, and DC-DC converters. The market demand for high-thermal-conductivity, high-stability polyurethane potting compound will continue to expand, and efficient dispersion and grinding processes will become key to enhancing product competitiveness for enterprises.
ZYE Technology's ZYTR-80E Plus three-roll mill solution not only solves the dispersion challenges in polyurethane potting compound production but also provides customers with full-chain support from process optimization to performance improvement, helping enterprises seize the development opportunities of the new energy vehicle industry and achieve product upgrades and market expansion.
Shenzhen ZYE Technology Co., Ltd.
No. 1268 Jiaotong Road, Wujiang Economic and Technological Development Zone, Suzhou (factory)
71 Xintian Avenue, Fuhai Street, Bao'an District, Shenzhen, China (factory)
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