Today’s vehicle manufacturers rely on materials with multifaceted characteristics. They must be durable, safe, and able to perform in various settings while also adhering to industry safety standards and comfortable for drivers to handle. There must also be an ample supply to support the production of approximately 93.9 million vehicles annually worldwide. Very few materials are capable of meeting all of these criteria. Liquid Silicone Rubber (LSR) is among the few.
LSR can operate in extreme temperatures, endure exposure to chemicals and physical forces while remaining durable and safe. It can also be molded into intricate and complex configurations and used alongside other materials to create unique components. These traits make it highly desirable for both manufacturers and consumers, as it is one of the most versatile and functional substrates in the automotive industry.
Explore below everything you need to know about LSR in the automotive/mobility industry, from its applications and future to the origins of its prevalence.
Common LSR Applications in the Automotive Industry
The automotive industry is increasingly utilizing LSR in many different applications. Common uses for LSR include:
- Seals and gaskets: Engines, transmissions and battery packs rely on LSR to provide a secure seal that protects and lasts. LSR’s strength and flexibility make it perfect for the job. It excels at protecting batteries and charging ports from water, dust, and other particles, and provides a barrier to keep oils and other fluids separate while withstanding extreme temperatures. Its lubricity and moldability also make it highly valuable, as it can be molded with precision for valve cover gaskets, thermostat seals, lip seals and more.
- Connector seals and housings: These components support a vehicle’s electrical and data-based functions, such as high speed data connectors, wiring harness connectors and touch-based digital interfaces. These types of applications require a material that is durable, nonconductive, and that provide a tight seal. LSR works perfectly for these requirements, it’s capable of protecting sensitive electrical components from water and other fluids while remaining flexible and safe to touch.
- Sensor and electronic component encapsulation: LSR is also prevalent in critical components used to protect electronic components and sensors that enable and enhance safety, performance, emissions control, autonomous driving, and connectivity functions. It provides a watertight seal while presenting a surface that is insulative and resistant to environmental conditions like heat and humidity. As a result, it has become extremely common in electric vehicles (EVs) in recent years.
- Hoses, tubing, and bellows: These components regulate the flow of fuel, coolant, oil and air throughout the vehicle, and LSR facilitates that circulation through its unique combination of flexibility and resistance to chemicals and temperature changes. Where other elastomeric polymers expand and crack over time, LSR retains its integrity and functionality.
- Vibration dampers and noise reduction elements: LSR’s elasticity and flexibility make it suitable for absorbing and dissipating vibrations. Automobiles use LSR for parts like engine mounts, vibration isolators, HVAC cushions and ventilation flaps, supporting a smoother, quieter, and more pleasant ride.
- Lighting components: Parts like LED diffusers, headlamp gaskets, optical lenses, and more incorporate LSR because of the material’s moldability and capacity for temperature resistance. Its durability allows it to support lighting components without impeding the light or warping.
- Interior touchpoints: LSR is used extensively in buttons, keypads, and other interactive components due to its durability and reliability for repeated use, returning to its original shape after compression. LSR is also hypoallergenic, odorless and provides a soft-touch surface. With its ability to resist heat, the material won’t warp or become too hot in direct sunlight, extending the lifespan of the interior touchpoints regardless of environmental conditions.
Why LSR Is the Preferred Material for Today’s Vehicles
The prolific use of LSR in the automotive industry can be attributed to the material’s resilience and durability. LSR offers many benefits for vehicles and drivers alike. These advantages include:
- Extreme temperature resistance: LSR can withstand temperatures between negative 40 degrees Celsius and 200 degrees Celsius, meaning it can be used in almost any environment and climate. Where other elastomeric polymers may degrade or become too hot to touch, LSR remains tactical and functional. It’s even flame-retardant.
- Chemical and environmental resistance: LSR is inherently inert, meaning it does not react when interacting with most chemicals. This inert quality allows it to come into contact with oils, coolants, cleaning solutions and other fluids without breaking-down, warping, contaminating the fluid, or damaging the vehicle. It is also resistant to water damage, UV rays, and oxidation. These qualities mean that LSR can perform under even the most strenuous environmental conditions.
- Design flexibility: The liquid molding process and LSR’s consistent flow makes molding thin membranes, parts with thick and thin sections and other complex design features easier to achieve, giving part designers greater flexibility. LSR can also be utilized in multi-shot injection molding for integrating LSR with multiple materials such as thermoplastics or alternative grades of LSR.
- Durability and longevity: LSR can withstand the extreme forces that are commonly incurred in a standard vehicle due to a mix of properties. It can flex and bend as the vehicle and its components vibrate and change position. It is also able to return to its original shape after being compressed. That resistance to strain is complemented by LSR’s natural durability and its extensive lifespan.
- Safety and compliance: All automobile components and materials must comply with national and international safety standards and regulations. LSR’s inertness, resistance to heat and flames, and insulating qualities make it safe to use while remaining compliant with fire safety and volatile organic compound (VOC) standards.
- Sustainability: LSR is lightweight yet durable, and as a result it supports increased fuel efficiency while supporting the principles of a circular economy. Manufacturers who embrace LSR’s sustainable qualities may experience a decrease in material acquisition and fabrication costs as a result.
Emerging LSR Applications in Next-Gen Vehicles
As vehicles evolve, new vehicles are realizing the benefits when utilizing LSR for components, especially EVs. Some innovative ways manufacturers are using this material include:
- Providing thermal insulation, containment, and protecting EV batteries and fuel cells from moisture and chemicals.
- Connecting driver-assistance systems via color-coded, vibration-resistant connectors.
- Integrating with new materials to create overmolded smart components.
- Connecting 5G sensors to touch-based vehicle consoles.
Additional applications in vehicles are sure to emerge as the mobility industry continues to adopt evolving technologies.
Custom Solutions for Your LSR Components from SIMTEC Silicone Parts
Today’s automobile designers and manufacturers rely on the ability of complex molding processes to create the LSR components they require. Whether you’re looking for sealed connectors, reliable sensors or hypoallergenic touchpoints, SIMTEC has the technical capabilities and LSR expertise to produce exactly what you’re looking. We offer diverse custom solutions, from design and prototyping to full-scale parts production, and inline secondary value-added processes.
For over 20 years, the SIMTEC team has partnered with the mobility sector to offer quality LSR parts. We are industry leaders and experts in LSR, LSR 2-shot and multi-shot injection molding, having produced billions of parts since the inception of SIMTEC in 2002.
To learn more about our custom LSR molding services, fill out our contact form today.
