From the outside, temperature sensors are simple and unassuming: a slender stainless-steel probe and a set of wires. They can be found everywhere, from HVAC ducts and refrigeration units to molding barrels and battery packs.
From the outside, temperature sensors are simple and unassuming: a slender stainless-steel probe and a set of wires. They can be found everywhere, from HVAC ducts and refrigeration units to molding barrels and battery packs.
But what’s going on inside that probe is much more complex.
One manufacturer we’ve worked with learned this the hard way. Their temperature probes were failing under high heat. The material inside the probe, which is responsible for transferring heat and protecting sensitive electronics, was cracking during thermal cycling. Over time, those fractures led to sensor failure. The problem wasn’t with the sensor design, but with the material protecting it.
At Copps Industries, we understand that at the edge of performance, material selection can mean the difference between reliability and failure.
The Hidden Demands on Temperature Sensors
Thermistors and electronic probes are used wherever accurate, responsive temperature sensing is critical, often in ranges from -58°F (-50°C) to 302°F (150°C), and in some cases far beyond. These sensors must:
- Transfer heat quickly and efficiently
- Withstand high temperatures
- Resist moisture intrusion
- Handle repeated thermal expansion and contraction
- Maintain adhesion to stainless steel housings
- Protect delicate internal wiring and electronic components
In real-world applications, that means surviving:
- Air handling units and ductwork in HVAC systems
- Industrial ovens and extrusion barrels
- Refrigeration and freezer environments
- Chemical processing tanks
- Battery packs and power supplies
- Data center server racks
These are demanding conditions for any material, especially those that can become brittle under heat. Copps’ engineers knew they could create a compound that would withstand such extreme environments, and that’s what we set out to do with A/B-136.
Product Spotlight: Copps A/B-136 Thermally Conductive Potting Compound
Copps’ A/B-136 was engineered specifically for applications where heat transfer, toughness, and durability need to work together. This thermally conductive adhesive and potting compound is commonly used in temperature probes found in HVAC systems, refrigeration units, and industrial equipment.
What sets A/B-136 apart? It delivers a rare combination of thermal performance and mechanical resilience.
- High thermal conductivity: Efficient heat transfer ensures fast, accurate sensor response.
- High temperature resistance: Performs in applications up to 450°F.
- Strong adhesion to stainless steel: Maintains probe integrity and long-term reliability.
- Tough and resilient, not brittle: Many thermally conductive materials sacrifice toughness, but A/B-136 protects structural integrity during thermal cycling.
- Low stress during cure and operation: Accommodates thermal expansion and contraction without stressing internal components.
- Accelerated heat cure options: Supports more efficient manufacturing processes.
Why Toughness Matters as Much as Conductivity
It’s easy to focus on conductivity numbers. But in high-temperature environments, conductivity alone isn’t enough. Many thermally conductive materials become brittle when exposed to repeated heat cycles. Over time, that can lead to:
- Microfractures
- Loss of adhesion
- Cracking under expansion and contraction
- Premature sensor failure
When the internal potting material cracks, the entire probe becomes vulnerable.
A/B-136 was formulated to avoid that tradeoff. Its toughness allows it to flex during thermal cycling without fracturing, maintaining consistent performance and protecting the sensor’s internal wiring and electronics from moisture and mechanical stress. This directly impacts long-term reliability.
Where A/B-136 Performs in the Real World
A/B-136 supports temperature-sensing applications across multiple industries:
HVAC & Building Systems
- Air temperature sensors in ductwork
- Smart thermostats
- Chillers and boiler sensing
- Refrigeration systems
- Heat pumps
Industrial & Manufacturing
- Plastic injection molding and extrusion barrels
- Chemical processing tanks
- Adhesive and resin mixing systems
- Industrial ovens and dryers
- Motor winding and bearing monitoring
Electronics & Data Centers
- Server rack temperature sensing
- Power supply thermal protection
- Telecom equipment
- LED thermal management
Energy & Battery Systems
- EV battery pack monitoring
- Charging system protection
- Grid storage battery packs
A thermistor probe may be small, but the environment it operates in isn’t. In each of these scenarios, reliable temperature measurement protects equipment, prevents failure, and supports system efficiency.
Copps Industries: Engineered for Performance at the Edge
At Copps Industries, we understand that the materials inside a component are just as critical as the component itself. By combining high thermal conductivity, elevated temperature resistance, and mechanical toughness, A/B-136 helps manufacturers build temperature-sensing systems that last under the most demanding thermal conditions.
If your temperature-sensing systems must balance conductivity, durability, and thermal resilience, Copps can help you optimize material performance from the inside out. Connect with our team to explore how A/B-136 fits your application.