Wacker unveils silicone suitable for electric vehicle busbar insulation, featuring a fire-resistant ceramic coating.
WACKER Introduces Fire-Resistant, High-Performance Silicone Rubber for Electric Vehicle Batteries
At the upcoming K 2025 International Trade Fair for Plastics and Rubber in Duesseldorf, Germany, WACKER is set to unveil their new extrudable silicone rubber, ELASTOSIL R 531/60, designed specifically for insulating busbars in high-voltage traction batteries for electric vehicles (EVs).
This innovative material offers a range of benefits, including flame resistance, high thermal stability up to 205 °C, and excellent electrical insulation. Key features and benefits include:
- Fire resistance: In the event of a fire, the cured silicone rubber forms a ceramic shell around the busbar, creating an electrically insulating layer that maintains protection and prevents short circuits at temperatures from 800 to 1,000 °C.
- Extrudability: The material allows cost-effective insulation of complex shapes like busbars through extrusion processing.
- High-temperature tolerance: ELASTOSIL R 531/60 withstands continuous operating temperatures up to 205 °C without degradation, crucial for the demanding thermal environment in EV battery packs.
- Flexibility at low temperatures: The material maintains flexibility at temperatures as low as minus 40 °C, which helps dampen vibrations and impacts from vehicle operation.
- Electrical reliability: ELASTOSIL R 531/60 prevents leakage currents and energy losses in busbars made of aluminum or copper, supporting the safe distribution of high voltages (300 V to 900 V) in modern EV battery systems.
- Adapted for rising battery voltages: Its high dielectric and thermal performance addresses the increasing electrical and thermal stresses from evolving EV battery designs.
By combining flame retardancy, robust electrical insulation, wide temperature tolerance, and ease of extrusion processing, ELASTOSIL R 531/60 enhances safety, performance, and cost-efficiency in EV battery busbar insulation.
The K 2025 International Trade Fair for Plastics and Rubber, taking place in Duesseldorf, Germany, from October 8 to 15, 2025, is where WACKER is showcasing this groundbreaking material. Visitors to the fair will have the opportunity to learn more about ELASTOSIL R 531/60 and its potential applications in the electric vehicle industry.
[1] Wacker Chemicals Corporation. (n.d.). ELASTOSIL R 531/60. Retrieved from https://www.wacker.com/en/products/silicones/elastomers/elastosil/elastosil-r-531-60
[2] Wacker Chemicals Corporation. (n.d.). ELASTOSIL R 531/60. Retrieved from https://www.wacker.com/en/products/silicones/elastomers/elastosil/elastosil-r-531-60
[3] Wacker Chemicals Corporation. (n.d.). ELASTOSIL R 531/60. Retrieved from https://www.wacker.com/en/products/silicones/elastomers/elastosil/elastosil-r-531-60
[4] Wacker Chemicals Corporation. (n.d.). ELASTOSIL R 531/60. Retrieved from https://www.wacker.com/en/products/silicones/elastomers/elastosil/elastosil-r-531-60
The introduction of WACKER's new fire-resistant silicone rubber, ELASTOSIL R 531/60, at the K 2025 International Trade Fair for Plastics and Rubber, is set to disrupt the electric vehicle (EV) industry by addressing the need for effective, high-temperature insulation for EV battery systems. Financial experts may find this development significant due to its ability to reduce production costs and increase efficiency in EV manufacturing, while energy providers could also benefit from improved safety and performance in electric vehicles powered by high-voltage traction batteries. The technological advancement of ELASTOSIL R 531/60 represents a step forward in the development of the electric vehicle industry and various connected sectors, such as the plastic, rubber, finance, and energy industries.
