Application of Silicone Rubber in New Energy Vehicles

Silicone rubber has excellent properties such as high and low temperature resistance, electrical insulation, and physiological inertness, and is widely used in the new energy vehicle industry. Here we mainly introduce the application of silicone rubber in the sealing of new energy vehicle cables and harnesses.

Application of silicone rubber in new energy vehicle cables

Compared with traditional fuel vehicles, hybrid and pure electric vehicles have added many high-voltage components such as power batteries, high-voltage distribution boxes, drive motors, and motor controllers, which also put forward new requirements for automotive cables. These cables are arranged in the front engine and chassis area with high temperature and small space, requiring cables to be soft, with a small bending radius, good high and low temperature performance. Secondly, with complex road conditions, cables must have good abrasion resistance and high mechanical strength. In addition, the instant large current demand on the cable wires during high or low speeds, especially under adverse conditions such as full load climbing, requires the cables to have short-term overload capacity.

The current insulation materials for automotive power cables on the market include cross-linked polyolefins and thermoplastic elastomers. The cross-linked polyolefin material can withstand temperatures up to 150℃, but the cable made of the material is relatively hard, making it inconvenient to install in the small space of the car body. It also requires irradiation cross-linking, which is a complicated process and is not suitable for large cross-section cables. The thermoplastic elastomer material can withstand temperatures no higher than 125℃ and is suitable for low-temperature grades of power cables. However, cable wires made of thermoplastic elastomer material have the risk of cracking after long-term use.

Application of silicone rubber in the sealing of new energy vehicle harnesses

Hybrid and pure electric vehicles require more harnesses and sensors, and harness seals are crucial for harness installation and sealing. Harness seals mainly include single wire seals and multi-cavity seals. The advantages of silicone rubber in the sealing of new energy vehicle harnesses include:

  • Stable performance at high temperatures, giving the cable a higher current-carrying capacity;

  • Self-lubricating surface, easy to insert terminals;

  • High mechanical strength ensuring that the terminal insertion process does not cause damage;

  • Ensuring long-term sealing effect;

  • Good heat resistance;

  • Good oil resistance;

  • Easy to shape and process with stable quality control, improving the stability of the finished product size.

In addition, silicone rubber is widely used in car window seals, car headlights, and other parts, providing human-friendly designs such as vibration reduction, noise reduction, fatigue resistance, and sheath design, as well as intelligent car lighting, to meet the comfort and safety of drivers and passengers.

Silicone rubber is one of the most important components of silicone resin. Due to its excellent characteristics, such as high and low temperature resistance, electrical performance, weather resistance, anti-aging properties, and physiological inertness, it is widely used in electronics and electrical, automotive, aviation, aerospace, machinery, healthcare, and consumer goods industries.