What are the advantages of Rogers foam in the field of new energy vehicles?

The application advantages of Rogers Foam in the field of new energy vehicles are mainly reflected in the high consistency between its material characteristics and the needs of the automobile industry, especially in insulation, cushioning, sealing, thermal management, electromagnetic shielding and so on. The following are its core advantages and specific application scenarios:

First, excellent electrical insulation and high voltage resistance.

High-voltage systems (such as battery packs, motors and electronic control units) of new energy vehicles (especially pure electric vehicles) require extremely high insulation materials.

Advantages:

Rogers foam (such as silicone foam and PORON® polyurethane foam) has the characteristics of high insulation resistance and breakdown voltage resistance, which can effectively prevent the risk of electric leakage and ensure the safety of the system.

The material meets the electrical safety standards of automobile industry (such as UL 94 flame retardant grade) and can still maintain stable insulation performance in high temperature environment.

Application scenario:

Insulation isolation between cells in the battery pack, high-voltage wire harness wrapping, and insulation gasket between the motor and the car body.

Second, efficient cushioning and anti-vibration ability

New energy vehicles are faced with impacts such as road bumps and component vibration during driving, which requires materials with long-term fatigue resistance.

Advantages:

Foam has the characteristics of high resilience and low compression permanent deformation, which can absorb vibration energy and reduce the damage of components caused by collision (such as battery core displacement and loose electronic components).

The material is soft and can be customized in thickness, which can adapt to the fitting of complex interfaces and provide uniform buffer support.

Application scenario:

Cushion between battery module and shell, vibration reduction of motor bracket, and shock-proof gasket of vehicle-mounted electronic equipment (such as display screen and sensor).

Third, reliable sealing and environmental protection functions

New energy vehicles need to deal with environmental challenges such as rain, dust and oil pollution, and the sealing performance directly affects the life and safety of components.

Advantages:

Rogers foam can form an effective barrier to prevent the invasion of liquid and dust (such as IP67/IP68 grade) through compression seal design.

The material is resistant to aging and chemical corrosion (such as electrolyte and lubricating oil), and is suitable for long-term use in harsh working conditions of automobiles.

Application scenario:

Battery pack shell sealing strip, charging port waterproof seal, door/window edge seal, motor end cover dustproof seal.

Fourth, the auxiliary role of accurate thermal management

The battery and motor system of new energy vehicles are sensitive to temperature and need materials to assist heat dissipation or insulation.

Advantages:

Some Rogers foam (such as thermal conductive silicone foam) has high thermal conductivity, which can conduct heat from heat sources (such as battery cells and power devices) to heat dissipation structures (such as metal casings and water cooling plates) and reduce local temperature.

Thermal insulation foam can block heat transfer (such as the thermal insulation layer between the battery pack and the cockpit), and prevent high temperature from affecting the passenger compartment or causing safety hazards.

Application scenario:

The thermal pad between the battery module and the radiator, the IGBT module of the motor controller conduct heat, and the thermal insulation layer between the battery pack and the car body.

Five, electromagnetic shielding and signal interference suppression

Electronic equipment of new energy vehicles (such as ADAS system and vehicle communication module) is vulnerable to electromagnetic interference (EMI) from high-voltage components.

Advantages:

Rogers can provide conductive foam (such as nickel-plated/copper-plated silicone foam), which can form an electromagnetic shielding layer by grounding to attenuate high-frequency interference signals and ensure the stable operation of electronic systems.

The material can customize the electromagnetic shielding effectiveness (such as ≥60dB) to meet the anti-interference requirements of different frequency bands.

Application scenario:

Vehicle-mounted radar (millimeter wave radar) shielding cover, battery pack electromagnetic shielding gasket, and electronic control unit (ECU) shell sealing shield.

Six, lightweight and design flexibility

New energy vehicles have strict requirements for lightweight and need to adapt to complex component shapes.

Advantages:

The low density of foam (such as 0.3-1.2g/cm) can reduce the weight of the whole vehicle and improve the cruising range.

Support die-cutting, stamping, adhesive backing and other secondary processing, and can customize various complex shapes (such as special-shaped seals and multi-curved cushion pads) to adapt to different installation spaces.

Application scenario:

Lightweight buffers between body structural parts, special-shaped foam clips for wire harness fixation, and filling seals for complex spaces in battery packs.

Seven, in line with the automotive industry standards and certification.

Rogers foam has passed many automobile industry certifications to ensure the reliability of materials:

Certification includes:

IATF 16949 (Automobile Quality Management System), RoHS (Environmental Protection Directive) and REACH (Chemical Registration).

Some materials have passed the standard tests of automobile manufacturers (such as enterprise specifications of Tesla, BYD and Contemporary Amperex Technology Co., Limited).

Advantages:

Simplify the supply chain audit process of automobile enterprises, shorten the product development cycle and reduce the compliance risk.

summary

Rogers foam has become one of the core materials of key components of new energy vehicles with its multifunctional integrated characteristics (insulation+cushioning+sealing+heat conduction+shielding). With the development of vehicle electrification and intelligence, its application in high-voltage safety, thermal management, electromagnetic compatibility and other fields will be further expanded to help car companies improve product performance and reliability.