Automotive · Western Europe · 2023
Tier-1 automotive supplier
The cork-NBR composite passed the OEM's full thermal-cycling protocol with no measurable compression set drift, replacing a fully synthetic incumbent and reducing the petrochemical content of the gasket by roughly 40%.
- Cycle test
- 1,000 h, –30 to 110 °C
- Compression set drift
- Within measurement noise
- Cork loading
- 35% by weight
- Petrochemical content
- −40% vs incumbent
Challenge
Develop a vibration-damping gasket for an EV powertrain enclosure that maintains seal performance across –30 to 110 °C with no compression set drift over 1,000-hour thermal cycling.
Approach
We supplied a fine-fraction cork (sub-1 mm) into the customer's NBR composite line at three different cork-to-NBR ratios. Test samples were cycled at the OEM's lab against a fully synthetic reference. The 35% cork loading delivered the best balance of damping and compression recovery.
Outcome
The cork-NBR composite passed the OEM's full thermal-cycling protocol with no measurable compression set drift, replacing a fully synthetic incumbent and reducing the petrochemical content of the gasket by roughly 40%.
Electric vehicle powertrains place sealing components under thermal cycles that combustion engines never imposed. The enclosure heats and cools faster, and the seal has to maintain pressure across the full range without taking a permanent set. The customer's existing fully synthetic gasket worked, but it carried a petrochemical content their sustainability team wanted to reduce.
We provided a fine cork fraction calibrated to enter their existing NBR mixing line without process changes. Three loading levels — 25%, 35% and 45% by weight — were compounded, calendered and die-cut at the customer's site. The OEM's lab ran each formulation through the full thermal-cycling protocol against the synthetic reference.
The 35% loading came through with compression set drift inside the measurement noise of the test. It is now in serial production for the program.
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