WACKER, a global chemical manufacturer specializing in high-performance silicones, polymers, and specialty materials, has introduced new silicone-based products designed to meet the rigorous demands of hybrid and electric vehicle (EV) power systems. The latest additions include a thermally conductive gap filler for power electronics and a flame-resistant silicone rubber for insulating high-voltage busbars.
SEMICOSIL 9649 TC
SEMICOSIL 9649 TC is a two-part, room-temperature curing silicone compound developed for use in EV power electronics.
The material offers high thermal conductivity (~4 W/mK) and reliable electrical insulation, supporting efficient heat dissipation in active and passive cooling systems.
It remains stable up to 150° C and performs consistently under thermal shock conditions ranging from –40° to +150° C, ensuring durability in high-stress thermal environments common in inverters and powertrains.
The material is also non-sag and shear-thinning, enabling precise, high-speed metering during automated assembly. When compressed between surfaces such as a heat sink and circuit board, it forms a conformal thermal interface layer that absorbs vibration while evening out surface irregularities.
ELASTOSIL R 531/60 is an extrudable silicone rubber formulated to insulate busbars in high-voltage EV batteries. In the event of a fire, the material ceramifies, forming a stable, insulating ceramic layer around the conductor to reduce the risk of short circuits under extreme conditions.
These products expand WACKER’s broader portfolio of silicone materials for e-mobility applications, including compounds for thermal management, high-voltage insulation, connector sealing, and fuel cell system protection.
Filed Under: Safety and Reliability, Technology News, Thermal Management