In recent years, the global electric vehicle (EV) market has seen rapid growth, with sales surpassing 14 million units in 2023, representing 22% of the overall market share. As EV adoption continues to rise, electric vehicle safety becomes a critical concern, with the battery pack's sealing performance playing a central role in overall safety.
In extreme environment, such as heavy rain, if pack seal fails, it can lead to electrical failures, short circuits, and leakage etc., bringing risks to the electric vehicle and passengers safety. To prevent these hazards, Generally, the battery pack seal needs to meet at least IP67 dustproof and waterproof requirement to ensure electric vehicle safe operation.
Material Selection: A Crucial Step
Choosing the right material is vital when designing battery pack seal. Considering factors such as sealing performance, operating temperature, cost, and corrosion resistance, many designers turn to foam materials. Among the options, silicone foam stands out due to its superior temperature resistance (-55°C to +200°C), ozone resistance, aging resistance, flame retardant, and low compression set, making it an ideal material for sealing applications.
Futureway® SRL-1140F is a prime example of silicone foam material. It provides good durability and excellent compression resistance over time. Additionally, it offers UL 94 V-0 certification rated for flame resistance. Finally, it meets IP68 dustproof and waterproof standards.
Precision in Compression and Seal Design
The compression ratio is a critical factor in achieving an effective seal. Insufficient compression can result in leaks, while excessive compression may lead to material stress relaxation or even damage. Therefore, it is crucial to control proper compression ratio during the design to ensure long-term sealing reliability.
The design of the pack seal must also consider its fit with the battery housing. Ensuring that sealing surface is as flat as possible, accurately placing bolts, and maintaining proper alignment during installation are essential for sealing performance. The narrowest width and effective width of the sealing gasket should also be factored into the design.
A scientifically designed sealing system, paired with the right materials, is the cornerstone of battery pack safety. With advanced technology and extensive industry experience, Futureway not only provides high-performance silicone foam materials but also offers professional technical support to help EV designers address battery pack sealing challenges, improving comprehensively electric vehicle safety and reliability.