In the automotive industry, the pneumatic system (commonly known as the “vent tank” or energy storage tank) is a key component that ensures the overall power response and smoothness of the vehicle. The inside of the vent tank often needs to maintain a high pressure of 35-40 Bar and withstand a wide temperature cycle test from -40 ℃ to 100 ℃. And the various connectors (sensor interfaces, solenoid valve interfaces, etc.) directly connected to the tank are the “throat” of the entire system: once the seal fails, it will cause air pressure leakage, system failure, and even endanger the safety and stability of the entire vehicle in severe cases. Therefore, selecting the appropriate sealing material for the automobile vent tank connector has become a technical challenge that vehicle manufacturers and component suppliers must focus on overcoming.
1、 Project Background
Application scenarios
Component location: Gas tank assembly near or on the chassis of the vehicle;
Working medium: Vehicle mounted high-pressure nitrogen or compressed air;
Work pressure: 35 Bar to 40 Bar (normal operating and safety reserve pressure);
Temperature range: -40 ° C (starting in cold conditions) to -100 ° C (engine compartment high temperature superposition);
Vibration and impact: The combination of road bumps and engine vibrations during vehicle operation.
Project objectives
Ensure that the connector is sealed without leakage under the long-term action of high-pressure gas;
Maintain reliability even after meeting extreme high and low temperature cycles;
Realize rapid solidification and improve production efficiency;
Control material and process costs to meet the requirements of mass assembly of parts.
2、 Main challenges
- Long term sealing under high pressure
The internal pressure of the car exhaust tank can reach up to 35-40 Bar during operation, and frequent inflation and deflation cycles can cause continuous mechanical tension and compression of the sealing gel. Stress concentration can easily cause microcracks or permanent deformation, leading to slow or sudden gas leakage. - Wide temperature environment test
Under low temperature conditions of 40 ℃, ordinary elastic sealing materials are prone to hardening and brittle cracking; At a high temperature of 100 ℃, material softening and creep may occur, leading to changes in the sealing geometry. Therefore, sealant should have excellent resistance to low temperature and toughness, as well as excellent high temperature stability. - Vibration and impact effects
The frequency and amplitude of vibration during vehicle operation are complex, and ordinary sealant may experience fatigue failure during long-term use in multi axis vibration, further increasing the risk of leakage. - Process stability and production efficiency
In mass production, assembly lines require colloids to have controllable operating viscosity and sufficient working time (not prone to premature setting), while quickly curing to shorten production cycles. For two-component adhesives, it is also necessary to ensure uniform mixing, consistent curing properties, and no deviation due to temperature or operational differences. - Cost and compliance requirements
The automotive industry has extremely high requirements for material compliance (such as REACH, RoHS, VDA specifications), and at the same time, it is necessary to achieve reasonable control of individual material costs while ensuring performance, in order to meet the cost control indicators of end vehicle manufacturers.
3、 Recommended plan
Based on the above challenges, we recommend SIPA 3000 thermosetting adhesive to our clients
Single component semi flowing, fast heating and solidification
Transparent or chromosomal organic silicone elastomer adhesive
■ It can bond a large number of substrates, such as stainless steel, glass, ceramics, etc., without the need for a primer
■ Has excellent flexibility and tear resistance
■ Additive curing system: no curing by-products
■ ROHS/REACH certified
Maintain elasticity and stability within the temperature range of -60 ℃ to+280 ℃
In high-pressure sealing fields such as automotive power systems and chassis control, a single material often fails to meet all extreme working condition requirements. Through the SIPA 3000 sealing solution, we have successfully overcome multiple challenges such as high pressure of 35-40 Bar, wide temperature range of -40-100 ℃, and vibration impact, achieving an efficient, safe, and economical sealing solution. If you also face similar high-pressure sealing difficulties, please feel free to contact us for consultation, and we will tailor the best sealing solution for you.
Tags: Sensor Sealing, Connector Sealing, Automotive Connector Sealing
