In the Year of the Fire Horse (Bingwu) 2026, continuous innovation in new-energy vehicle technology is driving ever-higher performance requirements for critical materials. Thanks to their unique and comprehensive properties, silicone materials have become an indispensable class of specialty materials that ensure the safe, reliable, and efficient operation of new-energy vehicles, playing a pivotal role in protecting and enhancing performance across the vehicle’s three core systems.

I. Key Applications of Battery Systems

The safety and lifespan of power battery packs are central concerns in the industry. Silicone materials play critical roles in these applications, including sealing, thermal conductivity, and electrical insulation.

Structural Sealing and Cushioning: The interior of the battery pack is highly sensitive to moisture and dust. Silicone potting compounds and sealants exhibit broad thermal stability—typically from –50°C to over 200°C—along with high elasticity and low shrinkage, providing long-term, effective sealing for cell-to-cell joints, module interfaces, and battery-pack housing seams. Their elastomeric properties also help cushion vibrations and impacts during vehicle operation, thereby protecting the cell structure.

Efficient Thermal Management: Thermal runaway of batteries is the primary safety risk. Silicone-based thermally conductive materials—such as thermal conductive gels, pads, and potting compounds—feature high thermal conductivity and excellent conformability, enabling them to fill the air gaps between heat-generating components and heat-dissipating parts, thereby establishing an efficient thermal conduction path. This helps to evenly distribute temperature within the battery pack, prevent localized overheating, and enhance both safety and cycle life.

High-Voltage Electrical Insulation: In battery management systems, high-voltage connectors, and other critical components, silicone-based insulating coatings, adhesives, and encapsulants provide reliable dielectric strength and insulation protection, while also exhibiting excellent resistance to high humidity, salt spray, and other harsh environmental conditions, thereby ensuring the long-term stability of high-voltage electrical connections.

II. The Function of the Electric Drive System

The performance and reliability of the motor and electric control system directly affect the vehicle’s powertrain performance.

Motor stator potting: Encapsulating the motor stator entirely with silicone potting compound allows it to cure into an elastic protective layer. Its primary functions include: securing the windings to withstand the electromagnetic forces and vibrations generated during high-speed rotation; enhancing heat dissipation through the material’s thermal conductivity; and providing comprehensive protection against moisture, electrical insulation, and corrosion, thereby improving the motor’s power density and service life.

Power module protection: Heat generation in IGBT/SiC power modules within electric control systems is highly localized. Silicone gel is a critical material for chip packaging; its low modulus helps absorb stress induced by thermal expansion and contraction, thereby preventing chip damage. At the same time, it offers excellent thermal conductivity and electrical insulation, ensuring the reliability of power modules under high-temperature and high-power operating conditions.

Auxiliary Component Protection: Silicone rubber is commonly used to encapsulate or seal sensors, cable connectors, and other components around electric motors, providing physical protection against high temperatures, aging, dust, and moisture.

III. Functions of Charging Facilities

Charging stations, particularly charging guns, are subjected to high voltage, large current, frequent plugging and unplugging, and harsh outdoor conditions.

Charging gun assembly: Silicone rubber is extensively used in charging gun handles, housing seals, and internal insulation and potting. This material retains its elasticity across extreme cold and high-temperature environments, ensuring smooth plugging and unplugging as well as a tight seal; its inherent flame-retardant properties meet stringent fire-safety standards; and its hydrophobic nature effectively prevents rain and snow from penetrating.

Sealing and Bonding of Charging Piles: The structural sealing of outdoor charging station cabinets, as well as the bonding of windows and nameplates, require materials with long-term weather resistance (including UV resistance, ozone resistance, and resistance to high–low temperature cycling) and durability; silicone sealants can meet these requirements.

Internal Circuit Protection: The power modules and control boards inside charging stations require thermal management using silicone-based thermally conductive materials, as well as conformal coating with silicone to provide three-proof protection against moisture, corrosion, and environmental contaminants, thereby enhancing operational stability in harsh environments.

Conclusion

The application of silicone materials in new-energy vehicles hinges on their unique set of material properties: broad-temperature-range stability, high elasticity, excellent electrical insulation, superior thermal conductivity, weather resistance, and flame retardancy. These characteristics systematically address key engineering challenges, including high-voltage electrical insulation, efficient heat conduction, sealing in complex environments, and mechanical stress buffering.

Currently, new-energy vehicles are advancing toward 800V and higher voltage platforms, ultra-fast charging, and greater energy density, placing increasingly stringent demands on the performance of supporting materials. The chemical structure of silicones is highly amenable to design and optimization; through molecular modification, it is possible to continuously develop next-generation products with enhanced thermal conductivity, reduced internal stress, improved adhesion, or easier processability—thus meeting the needs of future technological advancements.

In the Year of the Horse (Bingwu) and throughout future industrial development, silicone materials will continue to serve as one of the critical foundational materials, providing a robust material basis for enhancing the safety, reliability, and performance of new-energy vehicles.