Silicone Foam in Electric Vehicles:Material with Wide Applications And Advantages in The Electric Vehicle Industry

The silicone foam material is a type of porous, low-denThe silicone foam material is a type of porous, low-density, and low-elasticity elastomer made from silicone raw rubber, fillers, vulcanization accelerators, and foam rubber. Due to its high elasticity and sound insulation properties, it is widely used in daily life. It is commonly used as vibration-absorbing pads, sealing gaskets, sound-absorbing materials, insulation layer materials, and airline thermal insulation materials.

According to the cell structure, silicone foam can be classified into three types: closed-cell type, open-cell type, and mixed type. The density of silicone foam can vary depending on the manufacturing process. Typically, the density of silicone foam ranges from 0.16 to 0.20 g/cm3, making it suitable for applications such as car seats and headrests. In contrast, conventional silicone rubber foam materials have a density of 0.45 g/cm3 and are commonly used for gap filling in sealing and shock absorption parts.

One of the key features of silicone foam is its flame retardant properties. Adding flame retardants to silicone foam enhances its flame retardancy, with some grades achieving UL94-V0 certification. This property makes it particularly useful in the electric vehicle industry, where fire safety is crucial. By incorporating silicone foam into electric vehicles, the risk of fire caused by combustion can be significantly reduced.

However, the addition of physical fillers to silicone foam can negatively impact its electrical insulation properties. As the amount of filler increases, the volume resistivity and surface resistivity of the foam generally decrease, while the dielectric constant and dielectric loss factor tend to increase. Therefore, it is important to carefully consider the filler content when designing silicone foam for electrical applications.

In the electric vehicle industry, silicone foam plays a crucial role in protecting the battery core from potential hazards. The battery core is the source of kinetic energy for electric vehicles, but it also poses safety risks due to its potential to overheat and cause damage. Silicone foam helps prevent deformation caused by thermal expansion and contraction during charging and discharging cycles. Its excellent durability, low shrinkage, and impact absorption properties make it an ideal choice for use in battery insulation and outer frame sealing.

Moreover, silicone foam offers stable performance under different temperatures and has good waterproof sealing capabilities. It effectively prevents water seepage when used outdoors. Its long-term shrinkage damage is minimal, providing a certain level of resistance to shrinkage deformation. Additionally, its excellent flame retardant performance can effectively mitigate risks associated with thermal effects during battery operation.

When designing thermally conductive silicone sheets for new energy vehicle lithium batteries, it is essential to consider their thickness and strength according to different standards. These sheets must be well matched with the battery cover and have low internal stress to prevent bending and arching. By attaching thermally conductive silicone sheets to both the top and bottom of the battery pack, temperature control within 5°C can be achieved, ensuring stable battery performance and extending its service life.

Filling thermally conductive silicone sheets with good electrical insulation and thermal conductivity between batteries or between batteries and pipes can provide several benefits. Firstly, it changes the contact form between the battery and heat dissipation pipe from line contact to surface contact, increasing heat transfer efficiency. Secondly, it helps distribute temperature more evenly across single cells, reducing hotspots that could potentially damage the battery. Finally, it increases the overall heat capacity of the battery pack, leading to a reduction in average temperature and improved thermal management.

In conclusion, silicone foam material is a versatile elastomer with various applications in daily life. Its unique properties such as flame retardancy, electrical insulation, and thermal conductivity make it suitable for use in industries like automotive and electronics. With ongoing research and development, further advancements in silicone foam technology can lead to even more innovative solutions in these fields.