The widespread adoption of electric vehicles (EVs) has brought about unique engineering challenges, particularly in the design of battery packs, which are central to vehicle performance, safety, and longevity. One critical requirement is maintaining ingress protection (IP) ratings of IP67 or higher to safeguard against water and dust exposure. These ratings are essential to ensure compliance with homologation standards and to meet the demands of diverse terrains and operating conditions. Achieving effective sealing of EV battery packs is thus a key aspect of their design and engineering.
This study presents an in-depth analysis of sealing technologies employed in EV battery packs, focusing on four primary types: Adhesive-based sealants, Cure-In-Place Gaskets (CIPG), Foam Cut seals, and Rubber Gaskets. Benchmarking data gathered from more than 90 vehicle models across 20+ brands provide insights into adoption trends, historical shifts, evolution and interface requirements of different sealing solutions within the EV industry. The study examines possible reasons driving the choice of specific sealing methods, considering factors such as material properties, manufacturing costs, ease of application, and design considerations. While the analysis is based on industry trends and technical knowledge, it acknowledges that inferred strategies and preferences may differ slightly from the actual intentions or proprietary decisions of original equipment manufacturers (OEMs). Ultimately, this paper serves as a guideline for researchers and industry professionals, while serving as a foundation for further studies, offering critical insights into trends, challenges, and innovations in achieving optimal sealing methods for EV battery pack assembly.