Fluorosilicone rubber has recently achieved a key breakthrough in addressing the technical challenges of high-voltage fast-charging in new energy vehicles. With its unparalleled resistance to high voltage, corona discharge, and high-temperature electrolytes, this material has become the core material for sealing and insulation in 800V and above high-voltage platform battery packs, electric drive systems, and supercharging interfaces, constructing a critical line of defense for the super-fast charging safety and long-term reliable operation of electric vehicle battery systems.

Research confirms that specialty fluorosilicone rubber developed for 800V high-voltage environments maintains stable volume resistivity above 10¹⁶ Ω·cm, with corona resistance lifespan exceeding 800 hours, far surpassing the industry standard requirement of 200 hours. After 1,000 hours of immersion in high-temperature electrolyte at 120℃, it retains over 90% of its mechanical properties, with sealing force degradation less than 15%. Its innovative filler system endows the material with a thermal conductivity of 0.8 W/(m·K), strongly supporting battery thermal management under high-power fast-charging conditions.

In mass-produced high-end electric vehicle models, fluorosilicone rubber has been comprehensively applied in overall high-voltage battery pack sealing, inter-module insulation and fire barriers, and sealing rings for “flash charging” interfaces. Actual test data shows that during ultra-fast charging tests with peak power exceeding 400kW, related sealing components effectively resisted electrochemical migration and thermal shock caused by high-frequency pulse currents, ensuring absolute system safety while replenishing 400 km of range within 10 minutes. New battery pack designs based on this material have passed dual extreme safety tests of “no fire upon nail penetration” and “no water ingress after 10-meter deep water immersion”.

As ultra-fast charging networks evolve toward 1000V voltage platforms, iterative research and development of fluorosilicone rubber is accelerating simultaneously. The goal for the next-generation material is to achieve long-term temperature resistance at 150℃ and higher tear strength while maintaining existing excellent performance, to match future more extreme electrochemical and thermal environments. Industry chain reports indicate that the material’s technological leadership has already made it an “implicit threshold” in high-end electric vehicle competition. Its market scale is expected to exhibit exponential growth alongside the global adoption of high-voltage fast-charging technology, positioning it as one of the most certain growth tracks in the new energy vehicle materials field for the next decade.