English
Founded in 1945, Customer is one of India's largest automotive manufacturers, covering passenger vehicles, commercial vehicles, and electric vehicles. The company maintains a leading position in India's automotive market and holds more than 60% of the country's EV market share.
To support its rapid electrification strategy, customer has invested heavily in battery manufacturing capacity, including a 40GWh battery production facility designed to support future EV growth.
Heavy monsoon rainfall and flooding conditions require reliable sealing throughout the battery pack lifecycle.
Z-FOAM800 closed-cell silicone foam provides IP67/IP68 protection while maintaining sealing pressure after long-term compression.
Battery packs must withstand both sub-zero winter temperatures and prolonged summer temperatures above 45°C.
Z-FOAM800 operates from -40°C to 200°C and provides excellent resistance to UV, ozone, and environmental aging.
Conventional sealing materials suffer from stress relaxation over time.
With a compression set as low as 1.8%, Z-FOAM800 maintains sealing performance throughout the battery pack lifecycle.
Continuous vibration can cause cell movement and structural stress.
A combination of Z-FOAM800, TIF100 thermal pads, and TIS100 insulating materials provides cushioning and structural protection.
- 1000-hour 85°C/85%RH aging test
- ASTM D412 tensile strength testing
- Compression set evaluation
- Airtightness verification
- UL157 certification
- UL94 V-0 flame retardancy certification
All requirements were successfully achieved.
Test report about the compressibility:
| Test Results | ||
| Pressure(psi) | Compressibility(%) | |
|---|---|---|
| Z-FOAM840-10SC-A1 (1.17mm) | Z-FOAM880-10SC-A1 (2.17mm) | |
| 10 | 8.22% | 18.68% |
| 20 | 27.52% | 37.09% |
| 30 | 37.18% | 47.58% |
| 40 | 42.91% | 53.44% |
| 50 | 46.84% | 56.92% |
| 60 | 49.57% | 59.21% |
| 70 | 51.62% | 60.79% |
| 80 | 53.16% | 61.98% |
| 90 | 54.36% | 62.91% |
| 100 | 55.38% | 63.61% |
2023 Q2 – Project Initiation
2023 Q3 – Sample Validation
2025 Q3 – Battery Pack Qualification
2025 Q4 – Mass Production Supply
2026 Q1 – Vehicle Launch
2026 Q2 – Adoption in Next-Generation 800V Platform
- IP67/IP68 sealing protection
- Compression set as low as 1.8%
- Operating temperature range of -40°C to 200°C
- UL94 V-0 flame retardancy
- More than 500,000 pieces supplied
- Approved for customer’s next-generation EV platform
A: It offers better weather resistance, lower compression set, and a longer service life.
A: Yes. It can meet IP67, IP68, and even IPX9K protection requirements.
A:Yes. It supports custom die-cutting and can be adapted to various sealing groove designs.
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