The Challenge

Modern assemblies are under increasing thermal and mechanical stress:

• Higher power density and heat generation
• Mixed substrates with different coefficients of thermal expansion (CTE)
• Vibration, impact, and environmental exposure
• Pressure to reduce fasteners, weight, and assembly complexity

Traditional rigid adhesives may provide strength, but they often crack or debond under thermal cycling. Conventional thermal interface materials dissipate heat but offer little structural integrity.

The Plexus Solution

Plexus polyurethane structural adhesives are engineered to deliver both mechanical toughness and thermal performance, allowing adhesives to become an integral part of the system, not just a joining method.

Our Thermomechanical Polyurethane Portfolio:

• Bonds dissimilar substrates with minimal surface preparation
• Maintains durability across wide temperature ranges

Why Thermomechanical Matters

Plexus polyurethanes operate in the critical space between rigid structural epoxies and soft thermal materials like hybrids and silicones.

• Structural load sharing
• Stress relaxation during thermal cycling
• Heat dissipation through bonded interfaces
• Improved long‑term reliability

Result: fewer failures, longer service life, and simplified system design.

Key Industries Served

• Electric vehicles & energy storage
• Transportation & heavy equipment
• Industrial OEM & automation
• Power electronics & enclosures
• Data center infrastructure & power distribution

Core Portfolio Benefits

• Tough, elastomeric structural performance
• Low VOC / low odor formulations
• UL94 V‑0 options available
• High dielectric strength for electrically sensitive assemblies
• Cartridge and bulk dispensing compatibility

Plexus® Polyurethane Portfolio Overview

Polyurethane Products by Application

Plexus DT2325 – Flexible Structural adhesive for Thermally Dynamic Assemblies

Designed for assemblies where thermal cycling, vibration, and CTE mismatch drive failure risk.

Ideal for:

• Battery housings and modules
• Electronics enclosures
• Transportation panels and structures
• Mixed‑material joints requiring stress absorption

Maintains bond integrity as temperatures rise and materials move.

Plexus DT2430 – Structural Adhesive with Heat Dissipation

A balanced solution for assemblies needing strength, flame resistance, and improved thermal flow.

Ideal for:

• Power electronics housings
• EV and industrial control modules
• Structural bonding with moderate heat transfer needs

Structural bonding that helps manage heat without sacrificing toughness.

Plexus DT2630LD – Structural Thermal Pathway Adhesive

Engineered for assemblies where bonded interfaces contribute directly to thermal management.

Ideal for:

• EV battery systems
• Data center power distribution units (PDUs)
• Power electronics and cold plate assemblies
• Industrial systems with high heat retention/exposure

Typical Applications

• Battery enclosures and support structures
• Data center electrical and cooling infrastructure
• Structural sealing and bonding in thermally active systems

Why Plexus Polyurethane?

Compared to rigid systems, Plexus polyurethane adhesives:

• Better accommodate thermal expansion
• Simplify design by replacing mechanical fasteners
• Improve long‑term durability in thermally dynamic environments

Design with Confidence

Plexus thermomechanical structural adhesives deliver durability, flexibility, and thermal performance, enabling engineers to design smarter, lighter, and more reliable systems.

By: Chintan Patel, Product Marketing Manager