Material Development: From Concept to Custom Formulation in 14 Days.

Material Development: From Concept to Custom Formulation in 14 Days

Problem Statement

High-pressure sealing applications in EV battery cooling systems demand materials resistant to thermal degradation at 200°C and minimal compression set after 1,000 cycles. Standard EPDM compounds fail due to insufficient thermal stability and compression set exceeding 40%.

Material Science Analysis

Fluorocarbon elastomers (FKM) outperform EPDM and NBR in high-temperature environments due to their high fluorine content (66-70%). This molecular structure provides superior chemical resistance and thermal stability. HNBR, while offering good tensile strength, lacks the thermal endurance required for EV cooling systems.

Technical Specs

• Material: Custom FKM Compound
• Shore A Hardness: 75 ± 5
• Tensile Strength: 18 MPa
• Elongation at Break: 250%
• Temperature Range: -20°C to 210°C
• Compression Set: 15% (22 hours at 200°C)

Technical Comparison

Parameter	Custom FKM	EPDM	HNBR
Temperature Range (°C)	-20 to 210	-40 to 150	-30 to 180
Compression Set (%)	15	40	25
Tensile Strength (MPa)	18	12	20
Chemical Resistance	Excellent	Good	Very Good

Standard Compliance

RubberQ’s IATF 16949-certified process ensures batch-to-batch consistency. Custom FKM formulations comply with ASTM D2000 for material callouts and ISO 3601 for sealing performance. Adhesion testing follows ASTM D429 protocols, guaranteeing zero delamination in rubber-to-metal bonding applications.

For custom material compound development or IATF 16949 documentation, consult RubberQ’s engineering department.