Liquid silicone leak-proof seals specially developed for new energy vehicles, with excellent high and low temperature resistance, electrolyte corrosion resistance and anti-aging properties, strong sealing stability, can effectively block water vapor and dust intrusion, suitable for sealing needs of battery packs, body joints and other parts, with long service life.
Material
Industrial LSR
Hardness
Shore A 50-70
Temperature
Certifications
Applications
-60°C ~ +220°C
Colors
Black, White, Gray, Customizable
# Liquid Silicone Leak-proof Seals for New Energy Vehicles
*95 Durometer High-Performance LSR Sealing Solutions for EV Critical System Protection*
Our 95 durometer Liquid Silicone Rubber (LSR) leak-proof seals are purpose-engineered to address the extreme sealing demands of modern new energy vehicle (NEV) systems, where component failure can lead to costly downtime, safety hazards, or regulatory non-compliance. Designed for long-term resilience in high-stress, temperature-fluctuating operating environments, these seals deliver reliable ingress protection, fluid compatibility, and dimensional stability far exceeding the performance of traditional EPDM, nitrile rubber, or thermoplastic sealing alternatives.
At the core of this product is a medical- and automotive-grade platinum-cured LSR formulation, calibrated to 95 Shore A hardness to balance exceptional compression resistance with the flexibility required for consistent surface contact across uneven mating surfaces. Unlike lower-durometer LSR seals, this 95A variant is optimized for high-pressure applications where seal extrusion, creep, or deformation would compromise leak protection, making it ideal for NEV systems that require zero leakage over 10+ years of vehicle service life. The seals are manufactured via precision injection molding with tight tolerance control, eliminating secondary finishing and ensuring consistent fit across mass production runs.
Key core selling points include IP68/IP6K9K ingress protection rating compatibility, resistance to EV-specific fluids (coolants, dielectric oils, battery electrolytes, and road salt), UL94 V-0 flame retardancy as standard, and compliance with global automotive safety standards including ISO 10993, RoHS 2.0, and REACH.
Injection molding process specifications for custom seal production:
The 95A durometer formulation eliminates seal extrusion under high pressure (up to 10 MPa) common in NEV cooling and hydraulic systems, while the low compression set ensures consistent sealing force even after 10,000+ thermal cycles between -40°C and 180°C. Unlike EPDM seals that lose 30% of their sealing force after 3 years of NEV operation, these LSR seals retain over 90% of their original compression force after 10 years of simulated use, eliminating the risk of coolant leaks, battery water ingress, or high-voltage connector arcing.
The platinum-cured LSR matrix is inherently inert to all common NEV operational fluids, including ethylene-glycol battery coolants, dielectric thermal management oils, lithium-ion electrolyte leakage byproducts, and winter road salt solutions. This eliminates the swelling, cracking, or material degradation that plagues nitrile rubber seals when exposed to new low-conductivity EV coolants, reducing unplanned maintenance costs for NEV manufacturers and end-users.
With a dielectric strength of 22 kV/mm and standard UL94 V-0 flame retardancy, these seals address two critical NEV safety priorities: preventing electrical arcing in high-voltage (400V/800V) components, and stopping flame spread in the event of a battery thermal runaway. The material is also low-smoke and non-toxic when exposed to high heat, complying with UN ECE R118 passenger compartment fire safety standards.
Manufactured via automated LSR injection molding with in-line vision inspection, these seals have dimensional variation of <0.05mm across 1 million+ production runs, eliminating fit issues common with cut or compression-molded rubber seals. The process also produces zero flash as standard, reducing secondary finishing costs and ensuring no loose particles contaminate sensitive battery or motor systems during assembly.
These 95A LSR leak-proof seals are deployed across four core NEV system categories:
* Sealing gaskets for battery pack upper/lower housing, IP68-rated for under-chassis water and dust protection
* Coolant manifold O-rings for cell-to-pack thermal management systems, resistant to 120°C continuous coolant flow
* Sealing plugs for battery module pressure relief valves and service access panels
* Busbar insulation seals for 800V high-voltage battery packs, providing electrical isolation and leak protection
* Inverter housing sealing gaskets, resistant to high vibration and 180°C under-hood operating temperatures
* Motor stator coolant jacket O-rings, compatible with dielectric cooling oils
* High-voltage motor connector interface seals, with IP6K9K washdown resistance
* Chiller and heat exchanger sealing gaskets, with low compression set to maintain leak tightness during 10,000+ heating/cooling cycles
* Coolant pipe connector seals, resistant to pressure spikes up to 10 MPa during fast charging
* Positive temperature coefficient (PTC) heater housing seals, with 200°C continuous temperature resistance
* DC fast charging port interface seals, with UV resistance and IP68 protection for exterior mounting
* On-board charger (OBC) housing sealing gaskets, with 1.2 W/(m·K) thermal conductivity option for heat dissipation
* High-voltage distribution unit (PDU) connector seals, with electrical insulation to prevent arcing between adjacent 400V/800V circuits
While this product is standardized at 95 Shore A for most high-pressure NEV applications, we offer custom durometer options for specialized use cases:
* 70-80 Shore A: Recommended for static sealing on uneven mating surfaces or low-pressure (<2 MPa) applications where higher flexibility is required
* 90 Shore A: Mid-range option for moderate-pressure (2-8 MPa) applications with frequent thermal cycling
* 95 Shore A (standard): Optimal for high-pressure (>8 MPa) applications where seal extrusion is a risk, including cooling manifolds and EDU housings
* Custom grades up to 98 Shore A available for extreme high-pressure hydraulic NEV systems
We support both standard and custom seal geometries to match your design requirements:
* Standard O-rings: AS568, JIS B 2401, and ISO 3601 size ranges available ex-stock, with cross-sections from 1mm to 10mm and outer diameters from 3mm to 800mm
* Custom gaskets: Complex 2D/3D geometries, including molded-in assembly features (locating pins, snap-fit tabs) and multi-component overmolded seals (LSR bonded to plastic/metal housings)
* Custom cross-sections: D-shaped, X-shaped, and lip-style seals available for dynamic sealing applications (e.g., charging port access doors)
All custom seal designs are validated via finite element analysis (FEA) to ensure optimal compression force, leakage resistance, and assembly fit before mass production.
Select material grades based on your application's regulatory and performance requirements:
* Standard Automotive Grade (default): RoHS 2.0 and REACH compliant, UL94 V-0 flame retardant, suitable for most under-hood and battery pack applications
* Low-VOC Grade: Post-cured to reduce volatile organic compound (VOC) emissions to <10 μg/g, compliant with ISO 10993 and Chinese GB/T 27630 for passenger compartment interior sealing applications
* High-Thermal Conductivity Grade: 1.2 W/(m·K) thermal conductivity for seals that require simultaneous leak protection and heat dissipation for power electronics components
* Food-Contact Grade: Compliant with FDA 21 CFR 177.2600 and EU 10/2011 for NEV food storage compartment and beverage cooling system sealing applications
We implement a 5-stage quality control process to ensure every seal meets NEV industry reliability standards:
All our 95A LSR leak-proof seals come with a 5-year performance warranty against manufacturing defects, with dedicated technical support available for seal design, material selection, and assembly process optimization.
