Battery Pack Seals For Electric Vehicles

Many automakers have announced that they will electrify their vehicle platforms and portfolios over the coming years. With this move towards increased electrification, battery packs will assume ever increasing importance as the key source of power for many types of vehicles.

The battery packs of most modern electric vehicles (EV’s) are quite different than those used in mobile phones or other portable devices. EV battery packs typically include hundreds or thousands of cells, arranged into modules, and usually surrounded by channels containing liquid coolant to keep the battery within its desired temperature range. While lithium-ion battery packs are the mainstay power source for most EV’s, automakers are moving toward solid-state battery packs with an eye toward launching them sometime during the 2020s.

EV battery packs: the function of seals

Heat and the ingress of moisture and other contaminants can severely degrade the performance of EV battery packs. For this reason, the seals that are used in the batteries must be capable of withstanding the effects of heat while protecting the battery from potential contaminants such as moisture and dirt.

In EV’s, battery packs are usually placed inside enclosures consisting of an upper and lower housing. Gaskets or seals are used to separate these sections and prevent the ingress of water, dust, moisture, and salt into the battery pack. Should these elements find their way into an EV battery pack, battery life and performance can be significantly degraded.

Besides sealing out the elements, battery pack seals help to control and regulate heat produced by the battery pack, and they also prevent the fugitive emission of gas and liquids. Finally, electric vehicle battery pack seals perform an important function in helping to dampen noise and vibration that could degrade the battery pack or annoy vehicle occupants.

Besides the ability to seal the battery pack from temperature, air, dust and water, additional factors to consider when sourcing EV battery pack seals are fire-resistance and compression set.

EV battery pack seals from CRG

CRG produces and supplies battery pack seals for EV applications. These seals are produced under strictly controlled conditions in our ISO 9001-certified facility using the latest CNC production technology.

CRG manufactures EV battery pack seals from a range of elastomeric and sponge/foam materials. One of the materials we use for EV battery seal applications is a specially formulated silicone sponge. This material offers excellent sealing protection against the elements, and its excellent compression set and closed cell structure provides reliable sealing over a long lifespan. CRG’s silicone sponge can service a range of extreme temperatures (-60°C to 230°C), making it an ideal material to use in vehicle applications where temperatures can fluctuate widely.

For EV battery applications, CRG’s silicone sponge is flame retardant to UL94v-O and possesses low smoke and low toxicity properties, improving the safety, reliability and lifespan of EV battery packs. Available in a range of densities, CRG can help you choose the appropriate sponge for your EV application.

For over 25 years, CRG has helped leading automakers like General Motors, Ford, Chrysler, Toyota, and Mercedes-Benz to solve their toughest materials and parts challenges. From prototyping to finished part production, we have the experience and know-how to address your EV battery seal needs.

To find out more about the electric vehicle battery pack seals which CRG can supply, please contact our sales department at