When it comes to new energy vehicles, the first things that come to people's minds are batteries, motors and electronic control systems - the so-called "three-electric systems", which are the heart of the entire vehicle.
But very few people know that it is a group of invisible "champions" - silicone products - that keep this heart functioning normally, without fever, without electricity leakage, and without short circuits.
Today, let's talk about what role silicone plays in new energy vehicles.
1. The "Safety Guardians" in the Battery Pack
Battery power units are the most crucial and also the most "precious" components of new energy vehicles. They are sensitive to heat, cold, water and vibration - any issue not properly addressed can lead to performance degradation, or even a heat runaway situation.
Silicone plays three crucial roles here:
Heat conduction - "conducting away" the heat
During the charging and discharging process of the battery, a large amount of heat is generated. If the heat cannot be dissipated, excessively high local temperatures will lead to a decline in the battery's capacity and even cause thermal runaway.
Thermal conductive silicone potting compound is widely used for the connection between battery cells and modules, efficiently conducting heat to the heat dissipation plate - 4-22. The thermal conductivity ranges from 0.6 W/m·K to 12 W/m·K, meeting the heat dissipation requirements of different scenarios.
In simple terms: Silicone is the "heat sink" of the battery, preventing it from overheating.
2. Sealing - Keeping water and dust "out"
The battery pack is most vulnerable to two things: water and dust. Once they get in, it could cause a short circuit in the mild cases or lead to complete failure in the severe cases.
The silicone rubber sealing ring can maintain elasticity within an extreme temperature range of -60℃ to 200℃, effectively preventing the intrusion of rain, dust and electrolyte corrosion. The pre-expanded sealing silicone rubber is widely used in the sealing of the upper cover of the battery pack and the box body, achieving an IPX8 level of sealing effect.
In simple terms: Silicone is the "waterproof cover" for the battery, preventing any water from seeping in.
3. Flame retardant - "Stopping" the flames
This is the most formidable line of defense.
Wacker Chemical has launched a new type of flame-retardant silicone rubber. When exposed to extremely high temperatures, it transforms into a ceramic-like substance, forming a barrier at 1000℃ to prevent the spread of flames. The organic silicone resin-based fiber-reinforced composite material possesses unprecedented fire resistance and thermal insulation properties.
Some enterprises have launched organic silicon sealing materials for power batteries with a density as low as 1.05g/cm³. Compared with traditional products, they can reduce weight by 25% and also possess UL94 V-0 level flame retardant performance. They can maintain elasticity within the temperature range of -50℃ to 200℃ for a long time.
In simple terms: Silica gel serves as the final "firewall" for the battery.
II. The "Insulation Armor" in High-Voltage Wiring Bundles
The operating voltage of new energy vehicles is generally above 300V, and some 800V high-voltage platforms even have extremely high requirements for insulation performance.
If the insulation of the high-voltage wiring is not adequate, it may cause leakage of electricity in the case of minor issues, or even lead to a fire in the case of more serious problems.
Here, silicone rubber acts as the insulation armor. The insulation coating for the drive motor winding coils is made of high-temperature resistant silicone rubber, which can withstand continuous high temperatures above 150℃. The sealing piece at the connection point between the on-board charger and the high-voltage wiring also maintains sealing during long-term vibration and can prevent arcs or short circuits.
In simple terms: Without the insulation protection provided by silicone, high voltage electricity would be "unprotected" and potentially dangerous.
III. The "Waterproof Expert" in the Connector
The connectors of new energy vehicles have to withstand high pressure, high temperature, frequent plugging and unplugging, and long-term vibration. Any malfunction at any of these stages could lead to signal interruption or short circuit.
Traditional materials tend to age and lose their sealing properties over time.
Eiken Organic Silicon has launched the liquid silicone rubber material BLUESIL™ LSR 3935, which has specifically addressed this challenge. By leveraging the self-lubricating property of the material's surface, it reduces assembly wear. Its extremely low compression deformation capacity ensures long-term stability and maintains heat resistance even under extreme temperatures.
Liquid silicone rubber can stably carry up to 13A of current in connectors for battery management systems, motor controllers and charging interfaces, and maintain sealing performance even during frequent plugging and unplugging.
In simple terms: The silicone rubber ensures that the connector "can be inserted, removed, and does not cause an electrical leakage".
IV. The "Silent Master" Inside the Vehicle
New energy vehicles are quieter than fuel vehicles. However, precisely because of their quietness, road noise, wind noise and vibration become more pronounced.
Here, silicone rubber plays the role of shock absorption and noise reduction.
The silicone rubber shock absorbers in the drive motor suspension system absorb the vibrations generated during high-speed operation.
The silicone rubber bushings of the chassis suspension system absorb jolts and shocks.
The sealing strips at the door and window gaps prevent wind and rain, absorb vibrations and reduce wind noise.
In simple terms: The silicone material makes new energy vehicles "as quiet as a library".
What can Hongxiangda do?
Having talked about so many industry applications, finally, I also want to let you know:
Although Hongxiangda does not directly produce battery pack sealing rings or high-voltage wiring insulation sleeves, we have been deeply engaged in the field of silicone products for 15 years and have accumulated a complete process capability ranging from rubber mixing, molding, grinding, spraying to laser engraving.
If you need to customize silicone components in the new energy vehicle supply chain - whether it's dashboard buttons, interior seals, sensor covers or charging interface accessories - we can assist you throughout the entire process from design to mass production.
Our advantages lie in:
Complete process: rubber mixing, molding, injection, laser engraving, spraying, grinding, all completed in one step
Quality controllability: From raw materials to shipment, each process has standards.
Flexible cooperation: Quick proofing, short communication, prompt response
Silicone is the "hidden champion" of new energy vehicles. Hongxiangda is willing to be your "reliable partner" in the supply chain.
If you are looking for a supplier of silicone products, please feel free to come and have a chat with Hongxianda.