Silicone in the automotive industry – modern applications in vehicles

Silicone products are present in many components of passenger cars, trucks, and special-purpose vehicles. Silicone is used for the production of hoses, cables, seals, and profiles, which are commonly used in the automotive industry.

What is silicone?
Silicone is a type of synthetic rubber consisting of silicon, carbon, hydrogen, oxygen, and sometimes other elements. The main advantages of silicone include: temperature stability (temperature range from -60°C to +250°C), resistance to thermal aging, high elasticity and resilience, as well as insulating and damping properties. These unique properties make silicone rubber widely used in the automotive and aerospace industries.

High-temperature silicone – resistance to high temperatures in the automotive industry
Resistance to extreme temperatures is a feature that distinguishes silicone from other rubbers. The material has a wide temperature range from -60°C to +250°C (high-temperature profiles and other silicone products contain special additives that make them suitable for use at temperatures up to +300°C during transitional periods).

In vehicles, many components are exposed to high temperatures, oxidation, and harsh conditions. High-temperature silicone products are characterized by thermal stability and high resistance to prolonged heat exposure, which allows them to maintain their elasticity and shape without cracking, melting, or degrading. With the development of the automotive industry, the unique advantages of silicone sheets and profiles are widely used as effective solutions for insulation, sealing, and protection.

Silicone rubber products combine flexibility, chemical compatibility, and high performance under constant thermal stress. It is worth mentioning that silicone is resistant to high temperatures – its ignition temperature is exceptionally high, it does not ignite easily, and often self-extinguishes. In practice, this means that silicone products are ideal for use in engine compartments, cooling system hoses and turbochargers, turbocharging systems, components near the exhaust system, or vehicle doors.

One of the application areas is thermal insulation plates, which in the automotive industry create a thermal barrier between zones with different temperatures, e.g., protecting electronic components from overheating or limiting heat transfer to the vehicle body components. Thermal insulation protects components from heat, cold, and moisture.

Non-flammable silicone – fire safety in the automotive industry
Silicone is inherently non-flammable, meaning it does not support flames, does not drip when melted, and does not emit toxic fumes. Due to its unique chemical structure, silicone products exhibit excellent thermal stability and do not decompose easily. The material is ideal for applications where safety is a priority, especially in confined spaces such as cars, airplanes, or public transport vehicles. The fire resistance of silicone depends on its type and the optimal temperature range. High-temperature silicone sheets and profiles are ideal for use in car engines, where extreme temperatures prevail and ignition risk must be avoided.

Applications of fire-resistant silicone include protecting cables and ignition wires, sealing bulkheads (e.g., red automotive silicone, black automotive silicone), securing electric motors, protecting air conditioning components, and sealing battery enclosures. Silicone is also added to seat foams, dashboards, and seals in the vehicle cabin.

Silicone products and environmental resistance
The wide use of silicone in the automotive industry is possible thanks to the material’s high resistance to environmental factors such as ultraviolet (UV) radiation, ozone, and moisture. Unlike plastics, silicone rubber does not lose its elasticity, does not crack, fade, or degrade under prolonged exposure to sunlight or adverse weather conditions. The impact of moisture on silicone’s mechanical properties is minimal, allowing it to maintain full functionality for many years. The durability of the material makes it ideal for producing external components, such as window seals, covers, profiles, and other products exposed to weather conditions.

An important advantage of silicone is also thermal insulation, which plays a key role in stabilizing the operation of systems exposed to temperature fluctuations, including drive assemblies or electronic components. In vehicles with electric motors, temperature control directly affects the system's longevity. Silicone products also serve as an effective barrier that protects sensitive electronic components from moisture, dust, and temperature changes. Practical applications of silicone resistant to environmental factors include automotive sensors and connectors, electronic device enclosures, engine compartment seals, and body components exposed to weather conditions.

Other properties and advantages of silicone rubber
Chemical resistance
Resistance to a wide range of chemicals is one of the features that determine the use of silicone in the automotive industry. Silicone rubber is resistant to oils, greases, operating fluids, and aggressive cleaning agents. The durability of silicone sheets allows them to be used for manufacturing components that come into direct contact with such substances, ensuring long-term durability in various chemical environments. Moreover, high-temperature silicone retains its mechanical and sealing properties even when exposed to technical lubricants, coolants, detergents, or cleaning agents used in servicing.

Silicone hoses are used in applications requiring high resistance to elevated temperatures and aggressive chemicals. They are widely used in fuel systems, cooling systems, and other critical automotive applications exposed to chemicals for extended periods.

Practical applications of silicone in the automotive industry include sealing the oil pan, covering cables and bundles that protect installations from contact with oils and fuels, or covering vehicle surfaces (silicone technical coatings protect selected components from chemical corrosion). It is also worth mentioning that automotive silicone sheets are used as spacers and protective barriers. They are used for applications requiring protection and effective sealing of components from unwanted leaks and the action of aggressive chemicals. Additionally, sanitary silicone maintains high cleanliness and hygiene and is suitable for sterilization, which is important in the food or medical sectors.

High flexibility
High resilience and flexibility are key features that determine the wide application of silicone in the modern automotive industry. Silicone’s properties allow the material to remain flexible, not crack, and return to its original shape without permanent deformation. This highly resilient material does not deform or lose its sealing ability across a wide operating temperature range from -60°C to +250°C (high-temperature silicone products even up to +300°C).

Silicone’s excellent properties make it an ideal choice for vibration damping and sealing (e.g., sealing the oil pan). Due to its flexibility, silicone is used in many areas, such as engine components, sealing, and protection (e.g., electronic components), vibration-damping spacers from silicone sheets. Silicone’s flexibility allows it to maintain sealing even after repeated opening of doors, hoods, and covers without fatigue effects. The unique properties of silicone profiles also allow shaping and maintaining a tight fit, ensuring sealing without the risk of damage due to cracking under temperature exposure or UV radiation.

Excellent insulation and electrical protection
Silicone rubber is a natural electrical insulator. Due to its low electrical conductivity, it provides reliable protection for vehicle electronics against surges and moisture.

At Power Rubber, we understand the importance of excellent electrical insulation, which is why we supply high-quality silicone characterized by high dielectric strength, moisture resistance, and thermal stability. Our products (silicone profiles, silicone seals, silicone sheets) are perfect for automotive electronic systems and HVAC systems. Silicone profiles work excellently for protecting and insulating cables and wires.

Vibration damping and acoustic insulation
Silicone rubber is widely used for acoustic insulation and vibration damping. The development of the automotive industry requires the use of modern materials that must meet durability requirements, withstand high temperatures, and possess specific acoustic properties.

Technical silicone combines resilience, thermal stability, and the ability to absorb vibration energy. The material is resistant to permanent deformation under compression, making it durable against vibrations and impacts. It minimizes vibration transfer to adjacent components (e.g., electronic components), which directly contributes to reducing noise levels and improving acoustic comfort inside the vehicle.

Silicone supplied in the form of profiles reduces vibration, vibrations, and sound transfer. It is commonly used in areas such as door seals or engine mounts. Additionally, silicone materials are used wherever vibrations are generated by operating mechanical or electrical assemblies (e.g., car electrical systems). The wide use of silicone includes, among others, silicone bushings and washers at electric motor mounting points, silicone mats reducing vibrations in controllers, silicone seals for doors and hoods. Silicone covering surfaces also serve as protection for cables and cable bundles, eliminating high-frequency sounds resulting from mechanical vibrations of electronic components (the so-called buzzing phenomenon).

Applications of silicone in the automotive industry - examples
Below are typical applications of silicone in the automotive industry:

• Sealing and seals (headlight seals, cylinder head seals, drivetrain seals, valve covers, oil seals, electric motor seals)

• Silicone hoses (intake systems, fluid transfer under high pressure and temperature in applications such as fuel systems, cooling systems, turbochargers)

• Silicone sheets (production of seals in car engines, gearboxes)

• Electrical insulation (seals for electrical systems; spark plug insulation preventing sparks from jumping to neighboring wires; insulation for wires and cables protecting against heat and moisture)

• Vibration damping (silicone bushings reducing engine vibration and noise)

• Thermal insulation (silicone sheets and mats are used to protect electronics and wires from overheating)

• Silicone adhesives and sealants (e.g., red automotive silicone, black automotive silicone; effective sealing of components exposed to high temperatures and thermal expansion differences)

Silicone products available at Power Rubber store
The silicone products available in our offer are intended for industrial and technical applications, including those requiring high strength. We provide products (silicone sheets, silicone adhesives, silicone profiles, silicone seals, silicone hoses, etc.) made from high-quality silicone, which is characterized by excellent resistance to extreme temperatures, aging, and a wide range of chemicals.

At Power Rubber, we offer customization of silicone products based on a detailed analysis of the client’s needs. Based on our industry knowledge and years of experience, we precisely tailor technical parameters to meet the individual needs of the client resulting from working conditions and the requirements of a given application.

One of our specializations is mass production of products with a focus on high precision, repeatability, and minimizing material waste in the production process. We use various types of silicones in production based on the client’s specific needs. The proper material selection affects durability, reliability, and long-term operation.

Feel free to contact us at +48 22 292 40 24 or +48 505 16 03 03, or by email (Power@PowerRubber.com) or through our contact form.