As electric vehicles advance towards 800V high-voltage fast charging and extended range, the limits of battery thermal management systems are constantly being challenged. The performance of rubber seals and hose/components within the energy system directly determines the efficiency, safety, and service life of the battery pack.
The rapid evolution of the new energy vehicle industry is driving battery cooling systems towards greater efficiency, safety, and lightweight design. As critical components for sealing, connection, and vibration damping within the overall system, the performance of rubber products directly impacts battery heat dissipation efficiency, service life, and driving safety. With increasing battery energy density and the widespread adoption of fast-charging technologies, rubber components in NEV battery cooling systems are developing along four core directions, overcoming the performance bottlenecks of traditional rubber and meeting customized demands.
1. Adaptation to Extreme Conditions: High Temperature & Fluid Resistance
During fast charging, battery temperatures can reach over 120°C in some scenarios. Furthermore, cooling systems commonly use glycol-based coolants, refrigerants, and other media, which can cause aging, swelling, or cracking in traditional rubber.
Development Focus: Employing specialty rubber base materials like FKM (Fluoroelastomer/Viton), VMQ (Silicone Rubber), and HNBR (Hydrogenated Nitrile Butadiene Rubber), optimized through compound formulation to enhance temperature resistance range (-40°C to 150°C+) and fluid compatibility stability, preventing chemical reactions with coolants and refrigerants.
Customization Value: Customers can customize rubber components with precisely formulated compounds based on the specific coolant type (e.g., different glycol mixtures, CO₂ refrigerant) and operating temperature range, ensuring seal integrity even under extreme conditions.
2. Lightweighting & Integration for Vehicle Energy Consumption Optimization
The future demand for weight reduction in NEVs means traditional, single-function, and heavy rubber components are becoming obsolete, making integrated design key.
Development Focus: Reducing component weight through structural optimization and upgrades to lightweight rubber composite materials; integrating functions like sealing, damping, and flow guidance into single parts, thereby reducing the number of components and total weight.
Precision Customization: Customize integrated rubber components according to the battery pack's spatial layout and weight constraints, saving installation space and reducing overall vehicle energy consumption.
3. High Sealing Performance & Anti-Aging for Safety Assurance
The sealing integrity of the battery cooling system is directly related to the risk of coolant leakage. Long-term exposure to sunlight and high/low-temperature cycling can cause rubber aging, compromising sealing performance.
Development Focus: Utilizing precision molding processes to improve dimensional accuracy; combining special seal designs like lip seals or multi-seal structures to enhance sealing effectiveness; incorporating anti-UV, anti-ozone, and anti-aging additives to extend service life.
4. Compliance with Industry Environmental Standards
Global environmental requirements for the new energy vehicle industry are increasingly stringent. Rubber components must comply with regulations concerning low VOC (Volatile Organic Compounds), absence of heavy metals, and recyclability.
Development Focus: Utilizing environmentally friendly rubber base materials and solvent-free adhesives; optimizing production processes to reduce pollutant emissions; ensuring products comply with standards like EU REACH and RoHS.
More Stringent Challenges Render Traditional Rubber Components Inadequate
The evolution of NEVs places unprecedented demands on the battery cooling system, which directly impacts every rubber component:
Wider Temperature Tolerance Range: Components must remain stable under drastic temperature swings, from cold starts at -40°C to the risk of thermal runaway at 150°C.
More Complex Media Compatibility: Newer coolants with low conductivity and refrigerants (e.g., R1234yf) can be more aggressive towards materials over the long term.
Higher Sealing and Pressure Resistance Demands: Under 800V platforms, cooling systems operate at higher pressures, where even minor leaks can lead to insulation faults.
Stringent Longevity Requirements: Components must last the entire life of the battery (typically 8-10 years or more), avoiding costly repairs due to premature aging.
Customization Priorities Aligned with Future-Oriented Development Directions
Technological development for rubber components is focusing on the deep integration of material innovation and structural design.
Material Development:
Focus: Developing high-performance HNBR and FVMQ (Fluorosilicone Rubber) specifically compatible with modern coolants.
Key Materials:
HNBR retains the excellent oil resistance of NBR while offering higher continuous service temperature (150°C), oxidation resistance, and superior mechanical strength, making it ideal for cooling hose connections.
FVMQ combines the wide temperature range (-60°C to 200°C) of silicone rubber with the fluid resistance of FKM, making it a top-tier sealing material for new coolants and refrigerant environments.
Integration & Modularization Focus:
Combining multiple seals, connectors, and sensor wire grommets into a single molded component.
Integrating the cooling hose connector, inter-module battery seals, and high-voltage wire gland into a three-in-one design, reducing assembly steps, lowering leakage risks, and improving production efficiency.
Designing integrated sealing modules simplifies supply chain management and final assembly processes, enabling lightweighting and cost optimization.
Smart & Lightweight Components:
Embedding sensors within rubber components or employing lightweight structures.
Embedded Sensors: Micro pressure or temperature sensors embedded within seal rings enable real-time monitoring of seal integrity and coolant status, facilitating predictive maintenance.
Thin-Wall Design: Utilizing precise flow simulation and material reinforcement allows for thin-walled cooling hoses that reduce system weight while maintaining pressure resistance.
Precision Lifecycle & Reliability Validation:
Predicting component lifespan through accelerated aging tests and digital simulation.
We provide not just components, but also life prediction reports based on fatigue life simulation and material aging tests.
Customers gain data-backed confidence that our custom components will meet the design life target for their vehicle platform, reducing warranty period risks.
Why Partner with Us as Your Strategic Rubber Component Customization Partner?
Facing these technical trends, choosing a partner with forward-looking R&D and customization capabilities is crucial. The rubber custom manufacturer Pexxon Rubber possesses the following capabilities:
Material Laboratory & Formulation Capability: In-house mixing and testing facilities enable compound customization and compatibility validation specific to your coolant.
Collaborative Design & Engineering Experience: We can engage early in your product design phase, providing advice on integrated design and DFM (Design for Manufacturability) analysis.
Simulation & Validation Strength: We possess CAE capabilities (stress, fatigue analysis) and complete bench testing equipment to support product reliability with data.
Technical Reserves: We have proven application experience in specialty materials like HNBR and FVMQ, as well as in smart rubber technologies.
If you are seeking a rubber component partner for a new battery pack design or have higher requirements for your current solution's performance, we welcome you to contact us. Please provide your application scenario and performance challenges, and our technical team will offer you a dedicated technical pathway analysis and sample support.