Silicone Solutions for EV Charging Stations

In this article, we explore the best silicone sealants and adhesives used to maintain and construct EV (electric vehicle) charging stations.

Table of Contents

EV charging station

The Rise of Electric Vehicles

An EV charging station is a unit capable of charging the batteries of plug-in electric vehicles. Electric vehicles are set to account for 12% of all vehicles on the road by 2030. Additionally, the UK government is planning to place electric vehicle charging stations on every new UK home.

With this exponential increase in their demand, EV charging points are becoming very common structures around us. Increased demand means increased construction and maintenance. This requires high quality adhesives and sealants to put them together, boost reliability and reduce maintenance and repair issues further down the line.

How long does it take to charge an electric vehicle?

Electric vehicle batteries can be charged in as little time as 20 minutes or as long as 12 hours. This largely depends on the size, type and efficiency of the battery and the charging station used. For example, a 270kW Porsche Taycan can charge up to 80% in just 22 minutes, using a 150kW charger.

How Silicones Can Optimise EV Charging Manufacturing

DOWSIL™ silicone adhesives and sealants have a long proven history of providing lightweight protection and thermal stability, as well as improving efficiency and reducing costs within the application process. Additionally, silicone’s excellent weatherability properties allow EV charge points to be placed anywhere, providing reliable performance regardless of the harsh conditions endured.

Along with silicone’s excellent electronic protection, it is able to resist UV radiation, maintain superb flexibility over a large temperature range, form watertight seals, and exhibit dielectric properties. All these advantages make silicone a perfect material for sealing and putting together EV charging stations.

The types of silicones applicable to EV charging stations include: foams, adhesives and conformal coatings.

electric vehicle charging station


DOWSIL™ foams are great lightweight alternatives to traditional sealants and encapsulants, leading the way to more efficient processing. One common application for silicone foams is the shielding of battery packs.


Silicone adhesives are used for a variety of applications, including vibration control of large capacitors, electromagnetic shielding, adhering electronic components and lids, and house sealing. DOWSIL™ silicone adhesives are self-priming, long-lasting, and solvent-free.

Conformal Coatings for Electronic Protection

Silicone conformal coatings offer excellent stress relief when used on delicate PCBs (printed circuit boards) during thermal cycling. Various application demands can be met using DOWSIL™ conformal coatings thanks to their availability in a range of viscosities.

Applications of Silicones for EV Charging


Most charging stations are composed of a metal frame that acts as a structure, and the covers that close this frame.

This set of covers can be locked/fixed to the frame. As most of these stations are exposed to weather ageing, the covers must be sealed to reach the desired IP level.

Electronic & PCB Protection

PCB Protection

Silicones allow EV charging manufacturers to better protect their charge points from dust and moisture for a more reliable performance over an extended period of time.

Due to the harsh conditions endured by charging points, it is vital that manufacturers ensure a reliable performance a long period of time. Damp, dirty environments such as garages and car parks are renowned for faulty electronic products; making it essential that the industry’s main players cover all aspects of protection, from circuit boards, to the product casing.

DOWSIL™ Products for EV Charging Stations

DOWSIL™ 7091 Engineering Grade Silicone Adhesive

DOWSIL™ 7091 is a one-component, high performance engineering grade silicone adhesive specifically designed for applications demanding a strong but flexible bond. It cures at room temperature, is easy to apply, is non-sagging, and provides excellent adhesion to a variety of different substrates. It is ideal for bonding materials with different thermal expansion rates, such as plastic to glass or metal to glass.

DOWSIL™ 3-8209 Silicone Foam

DOWSIL™ 3-8209 is a two-component silicone foam that is designed to be directly dispensed and cured on the parts, forming an integrated compression gasket. It is able to cure at room temperature, stable and flexible over a large temperature range, of low to medium hardness, and easy to handle with 1:1 mix ratio.

DOWSIL™ 3-1965 Silicone Conformal Coating

DOWSIL™ 3-1965 is a one-component, transparent conformal coating that is designed for both rigid and flexible circuit boards, printed wiring boards (PWBs), and sensitive electronic components. It is able to cure at room temperature, has low viscosity which enhances flow, and cures to a soft elastomer which improves reliability against stress.

DOWSIL™ 744 Electrical Grade Silicone Adhesive

DOWSIL™ 744 is a one-component, white, non-flowing silicone adhesive that is ideal for use on electrical items. It cures at room temperature, requires no mixing, and provides high elongation for added stress relief. It is the recommended electrical grade adhesive, commonly used for bonding large components such as batteries or capacitors to PCBs.

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