Advantages of silicone sponge for electric vehicle applications
In recent years, the market for plug-in hybrid and battery-powered electric vehicles has increased at a rapid pace, as more people than ever before recognise the many eco-friendly benefits that come hand in hand with this type of vehicle. The market for hybrid and electric vehicles is set for unprecedented growth in the next decade.
Offering optimum value and performance, electric vehicles are now capable of delivering power, efficiency, and comfort due to advances in battery technology, design materials and manufacturing techniques employed to build electric vehicles.
A material that is generating particular interest in the world of electric motoring is silicone sponge, which can be used in a variety of electric vehicle applications.
What are the advantages to using silicone sponge for electric vehicle applications?
Silicone sponge can help address many of the challenges that are associated with battery-powered vehicles, helping manufacturers produce electric cars that are efficient, reliable and most importantly, safe.
The material offers a number of benefits that are advantageous in these applications, including:
- Provides incredibly low compression set for excellent recovery
- Offers thermal stability across a vast temperature range
- Provides excellent environmental protection in harsh weather conditions
- Resistance to thermal shock, oxidation, moisture, and chemicals
- Reduces vibration, squeak and rattle of the battery unit
- Excellent electrical insulation
Why is silicone used for electric vehicles?
Silicone is used in a variety of components for electric vehicles due to its beneficial properties, including:
Mitigating Thermal Runaway Risks
Thermal runaway is a potential hazard in battery design. This is where electrolytes within the lithium-ion cell combust and the pressure rapidly increases, creating a sharp and extreme spike in temperature. This spike is enough to cause a fire risk, which is obviously a major concern for electric vehicle manufacturers. Should a lithium-ion cell overheat uncontrollably, the inherent flame-retardant properties of specialised silicone sponge grades (often meeting standards like UL 94 V-0) can help slow or prevent the propagation of fire between cells, providing critical extra time for safety systems and occupants.
Silicone sponge with its high-temperature resistance and excellent flame resistance is the ideal material to prevent flame propagation should thermal runaway occur.
Reliable performance
Silicone solutions deliver the strength, resistance and durability required for reliable automotive applications. This is one of the main reasons why so many electric manufacturers are using this material.
Environmental sealing performance
As battery units are commonly placed on the underside of vehicles, they have to have excellent sealing performance to ensure water, dust and moisture ingress does not occur.
Silicone sponge provides long-lasting environmental sealing and resistance to prevent battery failure to prevent electrical failure.
Contribution to Lightweighting
In the drive to maximise EV range and efficiency, every gram counts. Silicone sponge, particularly when compared to some solid rubber or alternative sealing materials, can offer significant weight savings. Utilising lightweight materials like silicone sponge for seals, gaskets, and cushioning helps reduce the overall mass of the battery pack and vehicle, contributing directly to improved energy economy.
Long-Term Durability and Reliability
Electric vehicles operate in demanding conditions, requiring components that last. Silicone sponge provides excellent long-term durability, resisting degradation from common automotive challenges like UV radiation, ozone exposure, and repeated temperature cycles. This resilience ensures that seals and cushions maintain their integrity over the vehicle’s lifespan, contributing to overall reliability and potentially simplifying maintenance or repair access compared to materials that may degrade more quickly.
Examples of silicone sponge applications for electric vehicles
Within the design of electric vehicles, silicone is providing engineering and manufacturing solutions for:
- Module Separators: Cushioning and electrically insulating individual battery modules.
- Connector Seals: Protecting vital electrical connections from environmental factors.
- Enclosure Gasketing: Providing robust seals for battery casings, control units, and charging ports against dust and water ingress (meeting specific IP ratings).
- Vibration Damping Pads: Isolating sensitive electronic components from road vibrations.
Silicone Engineering are a leading provider of high-performing silicone rubber solutions fit for use across a wide range of electric vehicle applications. To find out more about the products we offer please get in touch.