Electric vehicle battery gaskets provide sealing and insulation between the battery cover and the battery case, both of which are usually made of lightweight aluminum. Rubber gaskets are also used in battery packs, which consist of groups of cells called modules and are located within the battery compartment. Compression or tolerance pads accommodate the expansion and contraction of battery cells. Between the battery module and a cooling plate, thermal interface materials (TIM) promote heat flow. Thermal runaway protection pads and polyurethane foam are used for fire suppression. 

As the transportation, heavy equipment, and aviation industries pursue vehicle electrification, Elasto Proxy is committed to providing companies with all of the custom sealing and insulation solutions that they need. Depending on how and where rubber products are used, EV battery seals may need to provide environmental resistance, withstand high heat and chemicals, and insulate against shock and vibration. Contact Elasto Proxy to discuss your application requirements or keep reading to learn about EV battery gaskets and what you need to consider.

Electric Vehicle Battery Cover Gaskets

Electric vehicle battery covers have a large sealing area and are subjected to harsh chemicals, high temperatures, and physical stresses. Form in place (FIP) gaskets are often used in high-volume, automated assembly (such as the automotive industry), but extruded rubber seals are a better choice for low-to-medium volumes, including prototypes. These extruded rubber gaskets for electric vehicles are available in both harder and softer durometers to support the proper amount of compression for a long-lasting seal. Extruded gaskets can also arrive ready-to-install and do not require dispensing and curing, as is the case with FIP.

EV battery cover gaskets use various elastomers, typically silicone or polyurethane foams, and include compounds that meet flammability standards such as UL 94 V-0. Typically, a gasket with a hollow section is used. In addition to sealing large gaps, these custom rubber gaskets can accommodate some movement within the application. During installation, the gasket may fit a groove in the battery cover or attach to a flat surface with a pressure-sensitive adhesive (PSA). Water jet cutting can create holes for bolts or screws that support long-term fastening. During EV battery maintenance, technicians can remove these fasteners and replace the rubber gasket if necessary.

Electric Vehicle Battery Compartment Gaskets

Elastomeric sealing and insulation is also used inside an electric vehicle’s battery compartment, where cells, modules, and packs all perform specific functions. Battery cells are the basic units of lithium-ion (Li-ion) batteries and include a cathode, anode, separator, and electrolyte. Battery modules are assemblies of cells that are separated by metal frames. Battery packs consist of battery modules and include a cooling system, which can use a phase change material (FCM), fin cooling, air cooling, or liquid cooling. In the Nissan LEAF, for example, a battery pack has 24 modules and each module has eight cells. 

Electric vehicle battery pack gaskets must seal and insulate the battery modules and, in turn, protect the battery cells. Often, EV battery pack gaskets are made of closed-cell silicone sponge that is UL 94-V0 flame retardant and has low smoke and low toxicity. These EV pack seals need to withstand the heat that’s produced by the battery pack, prevent the passage of gases and liquids, and dampen noise and vibration. They must also seal out water, dust, moisture, and road salt for proper ingress protection (IP). From TIMs to thermal runaway protection pads, EV engineers also need materials that meet specific standards.

Who Makes EV Battery Gaskets?

For over 30 years, Elasto Proxy has supplied the heavy equipment and transportation industries with custom rubber gaskets. As an AS 9100D and ISO 9001:2015 certified company, we’re also ready to help the aviation industry by providing EV sealing and insulation. At our manufacturing center near Montreal, Canada, our custom fabrication capabilities include water jet cutting, gasket bonding, gasket taping, and lamination. We use rubber extrusions made from silicones and other materials that we source from trusted suppliers. Elasto Proxy can help you with seal design and material selection, too.

Contact us for more information, or to request a quote for EV battery gaskets.    

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