Innovations in Rubber Materials: Meeting the Demands of Electric and Autonomous Vehicles

The shift in electric and autonomous cars away to internal combustion vehicles is not only redefining powertrains as well as electronics — it is totally redefining the automotive materials used throughout the vehicle manufacturing space. The actionable center of this evolution is a silent, but an important facilitator: rubber materials automotive. With the race to electrify and autonomate the industry, the need of advanced rubber on electric vehicles and rubber material on the autonomous vehicle has never been so strong. This change is proving to be not only a challenge of technology but also an opportunity to innovate.

Why Rubber Matters More Than Ever in EV and AV Eras

The history of automotive industry shows that rubber is a vital part of vehicles — seals, gaskets, tires, and vibration dampening systems. Nonetheless, the latest shift in the automotive world has placed value on reliable rubber materials to use in EVs, and high-performance rubber to be used in EV parts. The new-generation vehicles require materials which have the capability of tolerating higher voltages, variable thermal conditions and high safety requirements. The conventional rubber materials that were used to satisfy tenacious internal combustion automobiles are no longer enough with regard to functionality, recyclability and flexibility.

The Evolution of Rubber for Electric Vehicles: What’s Changing?

The high-voltage application is a design issue that challenges the electric vehicle architecture and insists on new technical solutions that are sparking the development of new rubber technologies to electric vehicles. Battery covers are an example which should be closed to moistures in-filtrations, thermo-cyclings and electro-magnetic emissions. New rubber compounds to EVs are in the development to address these requirements with higher dielectric strength, thermal conductivity and chemical resistance.

With battery electric vehicles (BEVs), EV component gaskets and thermal interface materials are requested to work efficiently beyond 150 degrees C. More stable materials such as fluorocarbon rubber (FKM) and silicone elastomers are becoming popular, but as researchers experiment even further, hybrid rubber material and nano-enhanced rubber compound are being tested.

The feature that makes these compounds distinctive is their durability besides the resistance to heat. Most parts in EV rubber categories have to be durable to support long operating cycles, without losing elasticity or degrading. It is there that the next-gen rubber technology in the automotive has its niche.

What about Sustainability?

The world is looking at the point where we have carbon neutrality and the push that the world needs in coming up with sustainable rubber materials automotive is increasing. The rubber sector is shifting towards bio-feedstocks, use of recycled rubber, and green manufacturing.

Biodegradable material like bio-based EPDM (ethylene propylene diene monomer) and silica reinforced natural rubber is giving hope. The solutions also have low Rolling resistance and long life of products as added benefits to reduction of dependence on petroleum based feedstocks. The automaker OEMs are also particular in their specs on automotive rubber materials that are sustainable, and that are part of their zero emissions/circular economic ambitions.

More surprisingly, novel rubber materials used in EVs based on dandelion roots and guayule, stand the chance of being tested in tire manufacturing, unexplored possibilities in supply of natural rubber.

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Kate Williamson More about AuthorKate, Editorial Team