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usheenthermal
As the global adoption of new energy vehicles (NEVs) continues to accelerate, managing heat generation within battery packs has become one of the most critical engineering challenges. Efficient thermal management not only improves the safety and lifespan of lithium-ion batteries but also ensures stable performance in extreme operating conditions. Among various materials, foam silicone (also known as silicone sponge) has emerged as an ideal solution for solving battery thermal issues due to its unique combination of thermal conductivity, compressibility, and environmental resistance.
1. The Thermal Challenge in NEV Battery Systems
Battery packs in electric vehicles generate significant heat during charging, discharging, and fast acceleration. Without effective heat dissipation, internal temperatures can rise rapidly, leading to:
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Uneven temperature distribution within battery cells
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Reduced electrochemical efficiency
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Accelerated aging or degradation of battery materials
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Safety risks such as thermal runaway
To maintain optimal performance, NEV manufacturers aim to keep battery temperatures between 20°C and 40°C. Achieving this requires materials that can both transfer heat efficiently and isolate components electrically — a balance that traditional thermal interface materials (TIMs) struggle to maintain.
2. Why Foam Silicone Is an Ideal Solution
Foam silicone thermal pads combine excellent heat conductivity with high elasticity and stability, making them particularly suitable for battery modules and electronic control units (ECUs).
(1) High Thermal Conductivity
Foam silicone can be formulated with thermally conductive fillers such as aluminum oxide, boron nitride, or silica, enabling effective heat transfer from the battery core to heat sinks or cooling plates.
(2) Elastic and Compressible
Unlike rigid materials, foam silicone’s low compression set allows it to fill micro-gaps between uneven surfaces, ensuring close contact and minimizing thermal resistance.
(3) Electrical Insulation
While transferring heat, foam silicone remains electrically insulating, preventing short circuits or dielectric breakdown between battery cells and conductive structures.
(4) Temperature and Chemical Resistance
Silicone maintains stable performance from -60°C to +200°C, making it ideal for NEV environments exposed to extreme weather and long-term cycling. It also resists UV, ozone, and chemical degradation, extending component lifetime.
(5) Lightweight and Easy to Process
Compared with traditional solid thermal pads, foam silicone offers low density and can be die-cut or laminated to fit complex battery geometries, reducing both material waste and assembly cost.
3. Applications of Foam Silicone in NEVs
Foam silicone materials are used in several key areas of the vehicle battery and power systems:
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Battery modules: between cells or between the module and cooling plate to improve heat conduction.
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Battery management system (BMS): for electronic component cooling and vibration isolation.
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Power distribution unit (PDU): for thermal insulation and sealing.
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Charging interface and inverter: to maintain temperature stability and prevent overheating.
4. Performance Example
A typical silicone foam thermal pad with a thermal conductivity of 3.0–5.0 W/m·K can reduce the maximum temperature rise in an EV battery module by up to 15–20%, significantly improving thermal uniformity and preventing local hotspots.
This directly enhances battery efficiency, cycle life, and safety performance, while reducing the risk of heat-induced failure.
5. Conclusion
Foam silicone represents a new generation of thermal interface material (TIM) technology for the NEV industry. By combining heat dissipation, vibration damping, and environmental durability, it provides engineers with a reliable solution to one of the most difficult aspects of electric vehicle design — battery thermal management.
As NEV battery energy density and charging speeds continue to increase, the demand for high-performance foam silicone materials will only grow, driving further innovation in both thermal conductivity and lightweight integration.
