Advanced Vacuum Potting Solution Enhances Reliability of Automotive Magnetic Components
Shenzhen Second Intelligent Equipment Co., Ltd. has successfully completed the design, manufacturing, testing, and delivery of the SEC-S400-ZL-4T Two-Component Vacuum Potting Machine for a RFID Antennas Worldwide Leader in Morocco, supporting the production of LF Antenna Coil components for automotive applications.
This project represents an important milestone for Second Intelligent in the field of automotive electronics potting solutions, demonstrating its capability to provide high-precision dispensing and vacuum potting systems for global electronic component manufacturers.
The customized potting system was developed according to customer’s requirements for:
● High reliability
● Precise two-component epoxy dispensing
● Bubble-free potting
● Stable production performance
● High production capacity
● Automotive-grade quality standards
1. Customer Background: A Famous Global Automotive Magnetic Component Manufacturer
A Spain-based company engaged in the development, manufacturing and commercialization of key inductive components for the automotive and industrial sectors., including:
● RFID Antennas
● LF antennas
● Power Transformers
● Inductors
● Chokes
● Current Sensors
● PLC Components
● AR/ VR Motion Tracking Sensors
Its products are widely used in:
● Automotive smart access systems
● Passive Keyless Entry (PKE)
● Electric vehicles
● Industrial automation
● Intelligent sensing applications
With increasing requirements for automotive electronic reliability, manufacturers require advanced encapsulation technologies to protect sensitive components against:
● Moisture
● Vibration
● Thermal cycling
● Environmental aging
2. Product Introduction: LF Antenna Coil for Automotive Smart Access Systems
The product involved in this project is an LF Antenna Coil module.
The component consists of:
● Injection molded housing
● Copper coil winding
● Magnetic core structure
● Electrical connection terminals
LF Antenna Coils are widely used in automotive smart access systems, where they communicate with vehicle key modules through low-frequency signals.
Typical installation locations include:
● Vehicle door handles
● B-pillars
● Center consoles
● Trunk areas
The product requires excellent mechanical protection and electrical insulation performance to ensure long-term reliability in harsh automotive environments.
3. Potting Process Requirement: Protecting the Coil Structure with High Reliability Encapsulation
Before potting:
●Internal coil structure is exposed
●Mechanical vibration may affect coil stability
●Moisture protection is limited
After potting:
●Complete filling of internal cavities
●Coil structure securely fixed
●Improved insulation performance
●Enhanced waterproof and vibration resistance
The potting process significantly improves:
✓ Product lifetime
✓ Environmental resistance
✓ Electrical safety
✓ Mechanical stability
✓ Production capacity
4. Potting Material Analysis: COOLMAG 32 LV Two-Component Epoxy Resin
For this application, customer uses:
COOLMAG 32 LV Two-Component Epoxy Potting Material
Technical characteristics:
Parameter | Specification |
Material Type | Two-component epoxy resin |
Color | Beige |
Mixing System | A/B Component |
A Resin Viscosity | 16,918 mPa·s |
B Hardener Viscosity | 15,778 mPa·s |
Hardness | Shore A 75 |
Thermal Conductivity | 1.49 W/mK |
Density | 1.82 g/cm³ |
Dielectric Strength | >5 KV/mm |
This material provides:
●Excellent electrical insulation
●Good thermal conductivity
●Strong mechanical protection
●Reliable filling performance
It is suitable for:
●Coil encapsulation
●Sensor potting
●Inductive component protection
●Automotive electronic modules
5. Second Intelligent Solution: SEC-S400-ZL-4T Vacuum Potting System
Based on customer’s product structure and material characteristics, Second Intelligent developed a customized:
SEC-S400-ZL-4T Two-Component Vacuum Potting Machine
The system integrates:
●Precision A/B material metering
●Dynamic mixing technology
●Vacuum potting process
●Customized product fixtures
●Stable production control
6.Advanced Potting Process Flow
The complete production process:
Manual loading to Front conveyor chain
↓
Press the start button
↓
Products into the potting machine
↓
Automatic vacuuming and dispensing
↓
Dispensing completed
↓
Products into Rear conveyor chain
↓
Manual unloading
7. Key Advantages of SEC-S400-ZL-4T Vacuum Potting Machine
1) High-Precision Two-Component Dispensing System
The COOLMAG 32 LV epoxy material requires stable mixing and accurate dispensing.
The SEC-S400-ZL-4T provides:
●Accurate A/B ratio control
●Stable material supply
●Consistent dispensing volume
●Reduced material waste
This ensures:
●Excellent product consistency
●Stable batch quality
●Lower production cost
2) Vacuum Potting Technology for Bubble-Free Encapsulation
LF Antenna Coil products have:
●Small internal cavities
●Complex coil structures
●Narrow filling spaces
Traditional dispensing methods may cause:
●Air bubbles
●Incomplete filling
●Internal voids
With vacuum potting technology, the SEC-S400-ZL-4T improves:
✓ Material penetration
✓ Filling completeness
✓ Product reliability
3) Customized Fixtures for Mass Production
According to customer’s product design, Second Intelligent developed customized fixtures to achieve:
●Accurate positioning
●Multiple product processing
●Fast loading/unloading
●Stable production cycle
The solution supports:
●Batch production
●Continuous operation
●Automotive manufacturing requirements
8. Application Industries of Second Intelligent Vacuum Potting Solutions
The successful delivery of the project demonstrates the suitability of Second Intelligent potting technology for various industries:
Automotive Electronics
Applications:
●LF Antenna Coil
●RFID antenna modules
●Smart key systems
●Sensors
●ECU modules
●EV electronic components
New Energy Vehicles
Applications:
●Battery Management System (BMS)
●On-board chargers (OBC)
●DC/DC converters
●Power electronic modules
Industrial Electronics
Applications:
●Sensors
●Inductors
●Transformers
●Control modules
9. From Process Evaluation to Production Delivery – Complete Project Capability
For this project, Second Intelligent provided a complete manufacturing solution:
✓ Product process analysis
✓ Material evaluation
✓ Potting process development
✓ Customized fixture design
✓ Equipment manufacturing
✓ Testing and validation
✓ Production support
Second Intelligent is not only a dispensing equipment supplier, but also a professional partner providing:
Process Optimization + Intelligent Equipment + Manufacturing Solutions
from prototype validation to mass production.
10. Why Choose Second Intelligent?
With years of experience in dispensing and potting automation, Second Intelligent provides advanced solutions for global manufacturers in:
●Automotive electronics
●New energy industry
●Consumer electronics
●Industrial automation
Main products include:
●Vacuum potting machines
●Two-component dispensing systems
●Precision dispensing robots
●Automatic potting production lines
●Conformal coating systems
Through innovative technology and engineering expertise, Second Intelligent helps customers improve:
●Production efficiency
●Product reliability
●Manufacturing consistency
Conclusion
The successful delivery of the SEC-S400-ZL-4T Vacuum Potting Machine for LF Antenna Coil production demonstrates Second Intelligent’s strong capability in automotive electronics encapsulation technology.
With growing demand for intelligent vehicles and electric mobility, reliable potting technology has become increasingly important for protecting sensitive electronic components.
Second Intelligent will continue providing advanced:
Smart Dispensing + Vacuum Potting + Automation Solutions
to support global customers in achieving higher-quality and more efficient manufacturing.
