Our Experience in the Electric Vehicle Industry

Electric vehicles are revolutionising automotive travel by delivering greener, more efficient transport across the world.

Electric vehicles, which are powered by one or more electric motors and use energy stored in rechargeable batteries, are lighter, have zero emission levels, and emit less pollution overall than internal- combustion engines.

Future automobiles and vehicles will increasingly rely on advanced electronics for control and functioning. The growth of modern electronics within automobiles has created new Sealing and Shielding issues and requirements for both battery packs and charging stations.

Sealing for EV vehicle battery packs

Battery gaskets for electric vehicles must create an excellent environmental seal but they can also help Thermal Insulation, Electromagnetic (EM) and Radio Frequency (RF) Shielding, and in the case of a Thermal incident passive fire protection.

• Protection from environment and heat issues

Environmental sealing and thermal insulation are required inside the battery compartment of an electric car, where cells, modules, and packs all perform different duties. The gaskets must seal and insulate the whole battery module, protecting all of the battery cells in the process. EV gaskets must be able to resist the heat generated by the battery pack, restrict the passage of gases and liquids, and dampen noise and vibration. For effective ingress protection (IP), they must also seal off the water, moisture, dust, and road salt.

• Protection from Electromagnetic Interference (EMI)

Strong electromagnetic fields exist in EV vehicles between the traction and auxiliary battery packs, in addition to the electric traction motor, DC/DC converter, power electronics controller, and other onboard equipment.

For example, Hybrid electric vehicles (HEVs), plug-in hybrid electric cars (PHEVs), and fuel cell electric vehicles (FCEVs) are all exposed to EMI because they include an auxiliary battery in addition to other electrical components. Safety-related sensors and GPS receivers in all-electric vehicles (xEV) are also exposed to interference from the battery yet rely on continuous RF signals.

• Protection from fire

A fire incident is often started within an EV battery pack when the battery exceeds its "thermal comfort zone" and heat transmission starts. The fire spreads from one cell to the whole battery pack, resulting in a battery thermal runaway.

EV battery thermal runaway is hazardous since adding water to a fire can generate severe flare-ups when water molecules split into explosive hydrogen and oxygen fumes. EV gaskets must resist flame, including flames caused by electrical overloads, component failure, and insulation failures.

In the incidence of a battery thermal runaway, the gasket must withstand extreme temperatures and following a fire to prevent leaking and spreading outside of the battery pack. EMI Seals has a range of gasket materials and thermal solutions that can meet UL 94-V0 flame resistance, provide initial passive fire protection and offer Fire and Smoke barriers to 1260°C and above.

Sealing of EV Vehicle charging station

An extensive EV charging infrastructure is critical for the electric car market's continuing expansion. Battery technology is currently creating longer-lasting, quicker-charging, and much stronger batteries that require shielding from heat and environmental challenges including rain, salt spray, UV, and Ozone.

Chargers of all varieties, which are frequently found in outdoor settings with extended lifetime expectations, should allow safe charging while shielding EV battery packs from heat and environmental challenges.

Since these chargers sometimes require servicing, the gasketing materials used to bind the housing structure should create a tight seal to keep out dust, moisture, and corrosion while also permitting serviceability.

Long-term protection, resistance to temperature variations, the heat produced by electronic parts, and resistance to deterioration from outside exposure are all requirements for gaskets.

For example, a closed-cell silicone sponge gasket, tested and authorised to flame standard UL 94 V-0, and obtaining an IP67 rating provides enhanced flame protection, gives a thorough sealing solution to an EV charging port.

EMI Seals and Gaskets Ltd has been developing EV solutions ranging from wet and dry battery seals to charging seals to trim and edge seals. Our revolutionary, pre-tested, and pre-approved material range along with our proven designs provide dependable and long-lasting environmental protection in addition to added toughness and longevity to enhance the future of the EV charging infrastructure.

For more information on bespoke gaskets and efficient sealing solutions for electric car applications, please contact us.