Ⅰ. The material revolution behind the upgrade of new energy vehicles

The global new energy vehicle market is expanding at an annual compound growth rate of over 28% (data source: MarketsandMarkts, 2023), and material innovation is the core driving force behind this change. As a representative of silicone materials, 107 silicone rubber (chemical formula: C6H18O2Si2) is reconstructing the performance boundaries of key components of new energy vehicles with its temperature resistance range of -60℃~250℃, 15-25 kV/mm dielectric strength and 0.5-1.5 W/m·K thermal conductivity (ASTM D5470 standard).

Ⅱ. Technical deconstruction of the four core functions
1. "Temperature regulator" of thermal management system
Technical principle:
107 silicone rubber achieves a longitudinal thermal conductivity of up to 1.8 W/m·K (UL 94 V-0 certification system) through a two-phase synergistic thermal conduction mechanism - phonon conduction of the silicon-oxygen main chain and thermal radiation diffusion of filler particles (such as Al2O3, BN).
Engineering value:
· Battery thermal runaway protection: A 0.5mm thick thermal conductive buffer layer is constructed between the battery modules to extend the thermal runaway propagation time by more than 300% (UN GTR 20 test)
· IGBT package heat dissipation: used in the vacuum potting process of power modules, reducing the chip junction temperature by 12-18℃ and increasing the inverter life by 30%

2. "Molecular barrier" of the sealing system
Structural characteristics:
The three-dimensional mesh cross-linked structure of 107 silicone rubber can form a dense protective layer with a porosity of <0.01 mm, and its water vapor permeability is only 0.05 g·mm/m²·day (ISO 7783 standard).
Typical applications:
· IP67 protection for battery packs: A continuous seal is formed at the joints of the electrical box through the in-mold injection process, passing the 48-hour salt spray test (GB/T 2423.17)
· High-voltage connector sealing: In-situ curing technology is used at the charging gun terminal to withstand 2,000 plug-in cycles (IEC 62196-3)

3. NVH-controlled "energy converter"
Dynamic characteristics:
The material's loss factor tanδ reaches 0.25-0.35 (ASTM D4065), and a vibration energy conversion rate of 62% can be achieved in the 20-500Hz frequency band.
Noise reduction engineering:
· Motor suspension system: As an elastic support, it reduces electromagnetic noise by 7-10dB(A) (GB/T 18655)
· Electric drive gearbox: Fill the gear meshing gap and reduce high-frequency howling

4. "Electronic moat" of high-voltage insulation
Electrical performance:
Volume resistivity>1×10¹⁵ Ω·cm, breakdown field strength>18 kV/mm (IEC 60243 standard), meeting the insulation requirements of systems above 3000V.

Safety protection:
· BMS circuit board three-proof coating: 0.3mm coating can resist 50kV/m electromagnetic interference (CISPR 25)
· Busbar insulation coating: Passed the rigorous test of partial discharge <5pC (IEC 60270)

III. Technical iteration of application scenarios

IV. Future direction of technology evolution

1. Functional integration: Develop multifunctional composite materials with thermal conductivity/electromagnetic shielding/stress sensing
2. Process innovation: Promote UV curing technology to achieve a 300% increase in production line beats
3. Sustainable upgrade: Research and development of bio-based silicone rubber (biocarbon content>30%)

V. Engineering selection suggestions
1. Matching verification: TGA thermogravimetric analysis (to confirm filler content) and DMA dynamic mechanical testing (to evaluate loss factor) are required
2. Process window control: The injection temperature is recommended to be 85±5℃, and the humidity is <30%RH to prevent bubble defects
3. Life prediction model: It is recommended to use the Arrhenius accelerated aging formula to calculate the 10-year performance attenuation rate

Conclusion
In the process of new energy vehicles moving towards 800V high-voltage platforms, CTC chassis integration and other technologies, 107 silicone rubber has evolved from a single packaging material to a system-level solution carrier. Its technical value is not only reflected in the material parameters themselves, but also in promoting the paradigm shift of the automotive industry from "mechanical dominance" to "electrochemical-material coupling innovation". Mastering the breakthrough of this kind of "invisible technology" will be the key to winning the competition for the next generation of new energy vehicles.
(Note: The data in this article are all from public documents and corporate white papers, and the specific application needs to be verified in combination with actual working conditions)