New Energy Vehicle Battery Pack Sealing & Thermal Management Solution

New Energy Vehicle Battery Pack Sealing & Thermal Management Solution

I. Industry Challenges: Dual Issues of Battery Pack Sealing and Thermal Management

Power batteries are critical safety components in new-energy vehicles. Exposure to water during driving, temperature fluctuations, and road vibrations can easily lead to water ingress and dust accumulation within the battery enclosure. Industry mandatory standards require battery packs to achieve at least an IP67 protection rating. Traditional sealing materials suffer from poor resilience and tend to degrade under high temperatures, resulting in cracks and leaks over time. Meanwhile, heat generated by cell charging and discharging is concentrated, and insufficient thermal insulation of seals may exacerbate heat buildup, increasing the risk of thermal runaway. There is an urgent need for an integrated material solution that simultaneously ensures sealing, thermal insulation, and shock absorption.

II. Core Sealing Solution: Z-FOAM800 by Ziitek Achieves Stable IP67 Protection

ZIitek's independently developed Z-FOAM800 closed-cell silicone foam is specifically engineered for battery pack flange sealing applications, providing a one-stop solution for waterproof and dustproof sealing, reliably meeting the long-term IP67 protection standard.

Highly Closed-Cell Airtight Structure: With a closed-cell rate exceeding 90%, its dense cellular structure effectively blocks pathways for moisture and dust infiltration, ensuring no leakage during vehicle submersion or rainy conditions. Compression permanent deformation is ≤5%, enabling stable rebound even after prolonged vibration and thermal cycling, preventing seal failure or gaps over time.

Full-Temperature Range Compatibility: Operates reliably within a temperature range of -40°C to 200°C, maintaining performance in extreme cold northern climates and intense summer heat. Resistant to ultraviolet radiation and salt spray corrosion, it meets the 10-year service life requirements of entire vehicles.

Enhanced Flame Retardant Safety: Certified with UL94 V-0 flame retardancy, it produces low smoke and is non-toxic. Additionally, it provides cushioning and vibration isolation, effectively mitigating assembly stress caused by thermal expansion/contraction of cells and vehicle body vibrations.

III. Integrated Collaboration: Sealing Materials Supporting Battery Pack Thermal Management

Z-FOAM800 combines sealing and basic thermal insulation with a thermal conductivity of 0.12 W/mK, effectively blocking external heat and cold interference from the battery enclosure. When combined with thermal conductive silicone sheets and liquid cooling structures, it forms a complete thermal management system.

The foam material isolates temperature transfer across the casing, reducing internal module temperature differences; its elastic properties fill assembly gaps in the enclosure to prevent localized heat accumulation; and its flame-retardant base material slows down heat diffusion, creating multi-layered safety protection. The material supports adhesive backing, fiberglass composites, and custom die-cutting, making it compatible with various battery pack architectures such as CTP, CTC, and CTB, simplifying assembly processes.

IV. ZIITEK’s One-stop Material Service

ZIITEK specializes in new-energy thermal sealing materials and offers customized Z-FOAM800 sealing gaskets tailored to automakers’ battery pack dimensions. We provide free sample production, performance testing, and thermal management material selection services, balancing mass production costs with safety standards. This enables us to deliver reliable, long-term integrated solutions for battery pack sealing and thermal management to OEMs and battery pack manufacturers.