Our silicone foam for new energy vehicles (NEVs) is a high-performance, automotive-grade custom material, exclusively developed for the core systems of electric vehicles, including battery packs, powertrains, charging ports, lighting, and interior components. Manufactured from high-purity platinum-vulcanized silicone raw materials, paired with halogen-free flame retardants and high-efficiency anti-aging additives, it adopts precision closed-cell foaming and calendering molding technology. Target
Our silicone foam for new energy vehicles (NEVs) is a high-performance, automotive-grade custom material, exclusively developed for the core systems of electric vehicles, including battery packs, powertrains, charging ports, lighting, and interior components. Manufactured from high-purity platinum-vulcanized silicone raw materials, paired with halogen-free flame retardants and high-efficiency anti-aging additives, it adopts precision closed-cell foaming and calendering molding technology. Targeted at the extreme operating conditions, ultra-high safety standards, and long service life requirements of NEVs, this product fully complies with UL94 V-0, RoHS, REACH, IATF16949, and GB automotive safety specifications. It effectively isolates external moisture, dust, road salt, and corrosive gases, cushions mechanical vibration and structural extrusion, stabilizes the internal thermal and electrical environment of the vehicle, and provides long-term, reliable protection for the stable operation of the entire new energy vehicle.
Core Performance & Structural Advantages
Featuring a uniform, dense closed-cell microstructure, flat surface, consistent thickness, and high resilience, this silicone foam fits perfectly with EV battery pack housings, module gaps, cover seams, charging interfaces, lighting systems, and interior component gaps, without causing abrasion, extrusion damage, or chemical corrosion to internal components. Specifically optimized for the harsh working characteristics of new energy vehicles, it breaks through the limitations of traditional EVA, PU, and rubber foams, delivering targeted, durable performance advantages:
- IP67-IP68 Ultra-High Sealing Protection: The compact closed-cell structure grants the product a high-level protection grade, completely blocking the intrusion of rainwater, humid air, industrial dust, sand, and road salt. It effectively avoids short circuits of battery management systems (BMS), electrolyte leakage, and component corrosion caused by moisture penetration, eliminating the core failure risk of NEVs due to poor sealing.
- Long-Lasting Shock Absorption & Vibration Damping: The high-resilience silicone material can absorb up to 85% of external vibration and impact energy, relieving extrusion and collision between battery modules, powertrain components, and the vehicle body during driving, acceleration, and deceleration. With a compression set ≤7%, it rebounds rapidly after long-term compression without permanent deformation, maintaining stable buffering performance throughout the 10+ year service life of the vehicle.
- Ultra-Wide Temperature Resistance & Extreme Weather Adaptability: Adapts to extreme operating environments ranging from -60℃ to 220℃, remaining flexible without embrittlement at subzero temperatures and not softening, deforming, or releasing volatile substances at high temperatures. Infused with professional anti-UV and anti-ozone additives, it resists long-term outdoor sunlight, wind, rain, and extreme weather, avoiding hardening, cracking, and yellowing, ensuring stable performance in all-weather driving conditions.
- UL94 V-0 High Flame Retardancy & Electrical Insulation: Complies with the strict UL94 V-0 flame retardant standard, featuring rapid self-extinguishing property, no molten drips, and low toxic smoke emission during combustion, effectively inhibiting flame spread and delaying thermal runaway of lithium-ion batteries in EVs. With a volume resistivity ≥10¹⁴Ω·cm, it delivers superior electrical insulation performance, preventing electric leakage, short circuits, and electromagnetic interference (EMI), fully meeting the high safety standards of large-capacity battery systems.
- Precision Customization & Easy Integration: Thickness ranges from 0.5mm to 50mm, with customizable length, width, and special profiles via precision die-cutting based on customer drawings. Dimensional tolerance is controlled within ±0.05mm, realizing a seamless fit with various EV structures, including battery pack housings, inverter shells, and charging port interfaces. The soft, non-stick texture enables quick positioning and assembly, boosting production line efficiency and reducing later maintenance difficulty.
- Eco-Friendly & Excellent Compatibility: Halogen-free, non-toxic, odorless, and free of heavy metals, fully complying with RoHS and REACH environmental protection standards. It has good chemical compatibility with battery cells, plastic components, metal frames, and circuit boards, with no adverse chemical reactions, and will not affect the performance and service life of new energy vehicle components.
Typical Application Scenarios
- Battery System: Sealing, gap filling, buffering, and fire protection for battery pack housings, module clusters, BMS shells, and thermal management components.
- Powertrain & Inverter: Shock absorption, insulation, and high-temperature sealing for electric motors, inverters, and power control units (PCUs).
- Charging System: Waterproof sealing and anti-aging protection for charging ports, cables, and connectors.
- Lighting & Interior: Shock absorption, sound damping, and environmental sealing for LED headlights, taillights, instrument panels, and interior trim components.
- Sensing & Communication: Vibration damping and environmental protection for radar sensors, cameras, and communication modules.
Precision Manufacturing & Strict Quality Control
Aiming at the high safety and long service life requirements of new energy vehicles, we implement the IATF16949 automotive-grade quality management system and carry out full-process quality control and multi-round rigorous testing to ensure product consistency and reliability:
- Automotive-Grade Raw Material Screening: Select high-purity platinum-vulcanized silicone raw materials, matched with special flame retardant, anti-UV, and insulating additives. All raw materials pass strict RoHS, REACH, and heavy metal detection to meet automotive environmental and safety standards.
- Precision Foaming & Molding Process: Adopt closed-cell precision foaming and high-precision calendering technology to ensure uniform cell distribution and consistent thickness. High-precision die-cutting equipment processes products with smooth edges, no burrs, and no degumming, avoiding damage to EV components during assembly.
- Comprehensive Performance Testing: Each batch undergoes 20 strict tests, including waterproof/dustproof test, compression resilience test, high and low temperature cycle test, flame retardancy test, electrical insulation test, UV aging test, and dimensional accuracy test, with a factory qualification rate of 99.8%.
