New Energy Vehicle Battery Pack Sealing & Thermal Management Solution

Customer Background

Founded in 1945, Customer is one of India's largest automotive manufacturers, covering passenger vehicles, commercial vehicles, and electric vehicles. The company maintains a leading position in India's automotive market and holds more than 60% of the country's EV market share.

To support its rapid electrification strategy, customer has invested heavily in battery manufacturing capacity, including a 40GWh battery production facility designed to support future EV growth.

Challenges & Solutions

Challenge 1: Long-Term Waterproof Sealing

Heavy monsoon rainfall and flooding conditions require reliable sealing throughout the battery pack lifecycle.

Solution

Z-FOAM800 closed-cell silicone foam provides IP67/IP68 protection while maintaining sealing pressure after long-term compression.

Challenge 2: Extreme Climate Conditions

Battery packs must withstand both sub-zero winter temperatures and prolonged summer temperatures above 45°C.

Solution

Z-FOAM800 operates from -40°C to 200°C and provides excellent resistance to UV, ozone, and environmental aging.

Challenge 3: Compression Set and Reliability

Conventional sealing materials suffer from stress relaxation over time.

Solution

With a compression set as low as 1.8%, Z-FOAM800 maintains sealing performance throughout the battery pack lifecycle.

Challenge 4: Vibration and Shock Protection

Continuous vibration can cause cell movement and structural stress.

Solution

A combination of Z-FOAM800, TIF100 thermal pads, and TIS100 insulating materials provides cushioning and structural protection.

Main Content

Project Background

As electric vehicles evolve toward longer driving ranges and higher safety standards, battery packs have become one of the most critical vehicle subsystems. Customer sought to improve battery pack protection and long-term durability under India's demanding operating conditions.

Traditional sealing materials were unable to fully meet the requirements of next-generation battery systems.

Key Solution Locations

• Battery enclosure sealing using Z-FOAM800
  
• Cell module cushioning using TIF100 and TIS100
  
• Side-wall thermal transfer using TIF thermal pads
  
• Liquid cooling interface enhancement using TIF100C
  

Validation Testing

Extensive validation included:

• 1000-hour 85°C/85%RH aging test
• ASTM D412 tensile strength testing
• Compression set evaluation
• Airtightness verification
• UL157 certification
• UL94 V-0 flame retardancy certification

All requirements were successfully achieved.

Timeline

2023 Q2 – Project Initiation

2023 Q3 – Sample Validation

2025 Q3 – Battery Pack Qualification

2025 Q4 – Mass Production Supply

2026 Q1 – Vehicle Launch

2026 Q2 – Adoption in Next-Generation 800V Platform

Project Results

• IP67/IP68 sealing protection
• Compression set as low as 1.8%
• Operating temperature range of -40°C to 200°C
• UL94 V-0 flame retardancy
• More than 500,000 pieces supplied
• Approved for customer’s next-generation EV platform