Efficient thermal conductivity!

In 2021, the global sales of electric vehicles will reach approximately 6.
8 billion, of which 70% will be pure electric vehicles (BEVs) and the remaining 30% will be plug-in hybrid vehicles.
The requirements are very demanding and the design is very different from traditional systems
.
Currently, the electric vehicle industry is increasingly turning its attention to materials such as silicones
.
It is reported that WACKER is working with relevant car manufacturers and suppliers to develop solutions for future vehicles
.

It is understood that the production and assembly of electronic components is a key application area of ​​silicone
.
Heat-resistant silicone potting compounds protect sensors and electronics from dust and moisture
.
Typically, to speed up processing, the parts where the components are bonded are cured in an oven, while silicones from WACKER form bonds at moderate temperatures without additional processing steps
.
In addition, UV-activated silicones from WACKER save even more processing time
.

Optical bonding effectively reduces reflected light

Large, curved displays have become standard in modern EVs, especially in the cabin, where traditional instrument clusters have been replaced by fully electronic instrument clusters with built-in displays and communication systems
.
However, the display needs to be stronger than traditional phone displays and not fail or freeze under vibrations and bumps
.
The same is true under high and low temperature conditions, and the display must withstand temperatures of minus tens of degrees Celsius and summer heat
.

Good readability of the display is also extremely important
.
Silicone gels from WACKER are transparent and non-yellowing, ensuring that optical displays meet the requirements
.
Firmly attaching the display module to the previous module eliminates internal reflective planes, and the silicone adhesive has about the same refractive index as the two adjacent materials, so when light passes through the two attached parts and the adhesive , as if it were spread in the same material
.

(Image courtesy of WACKER)

The process, known as optical bonding, is said to be particularly effective at reducing reflected light by up to two-thirds
.
Silicone gel can also protect the visible area inside the display device from dust and moisture, making the display more stable and the screen design more flat
.

Efficient thermal management keeps electric vehicles running reliably

It is reported that how to effectively dissipate heat from in-vehicle components during driving and charging of electric vehicles is still a major challenge for automakers, and efficient battery heat pipes are crucial
.
Lithium batteries can only perform optimally between 20°C and 35°C.
To ensure the battery's performance life, it must be protected against heat
.
Electric motors and their power management systems are also important sources of heat, which must also be dissipated to prevent damage or failure due to high temperatures
.

Efficient thermal management is critical to the reliable operation of electric vehicles
.
The use of thermally conductive caulk ensures a flexible yet strong bond between the component and the heat sink to drastically reduce resistance to thermal conduction
.
Thermally conductive gap fillers help cool components quickly by dissipating heat quickly due to their high thermal conductivity
.

Silicone gap filler has strong thermal and thermal conductivity

Power electronic components are mainly used to control and convert electricity
.
High temperatures can damage sensitive semiconductor structures, age transistors, and ultimately lead to component failure
.
Organic polymers cannot withstand thermal loads above 150°C, making silicone caulks the material of choice for thermal coupling
.

(Image courtesy of WACKER)

In addition to meeting the requirements for thermal resistance and thermal conductivity, the paste-like compound of silicone caulking agent, its rheological properties can also be adjusted to be able to cope with high-speed, high-automation automotive production processes
.
Here, the length of the molecular chain, the type of liquid silicone polymer, and the size and shape of the caulk particles are all key parameters for selection
.
For example, SEMICOSIL® 96x TC, a room temperature curing caulk that disperses quickly, reaches final modulus in just 5 hours at room temperature, and has thermal conductivities ranging from 2W/(m K) to 4W/(m K ) between
.

High-efficiency thermally conductive gap filler helps shorten production cycle

Thermal coupling between the battery module and the heat sink is required with thermally conductive caulk, which must have excellent aging resistance to prevent premature battery failure and must also be able to be quickly applied to larger surfaces
.

Make sure that the bottom of the cell and the heat sink are firmly bonded, and make sure that the filler does not generate any air bubbles in the gap of only a few hundred microns
.
For these applications, WACKER has developed a free-flowing and fast-dispersing caulk that can also be injected flawlessly into larger crevice surfaces, helping to reduce cycle times in large-scale production
.