Seal the Deal: Why Material Matters in Outdoor EV Charging Enclosures

As long as there’s innovation, there will always be opportunity for refinement. And EV charging enclosures are no exception. Because technology doesn’t arrive in a sealed box, there will always be a need to protect inner components from the elements — especially in outdoor use. 

That’s why materials matter for outdoor EV charging enclosures.

When designing an EV charging enclosure, there are two critical problems to solve:

1. Reliability. Nearly one in five public EV chargers don’t work when drivers need them most. Without a reliable charging network, EV adoption will stall.
2. Weather resistance. Outdoor enclosures face constant exposure to heat, cold, water and dust — forces that can compromise sensitive components.

The right materials can elevate your charger’s reliability and long-term performance. In this guide, we’ll look at high-performance solutions from Rogers that are designed to safeguard EV supply equipment (EVSE) from the elements.

Seals vs the weather: What’s at stake? 

Metal and polymer housing are generally durable enough to withstand long-term outdoor use. But it’s the components inside that need extra protection, since they are usually made from less resilient materials. And that’s where it’s critical to reinforce seams, joints, connectors with high-performance materials that maintain their integrity after long-term exposure. 

Heat: In direct sun, metal surfaces can quickly rise to 144°F and long-term exposure can cause gaskets and adhesives to expand, chemically degrade and lose their elasticity and strength, giving moisture and dust an entry point. 

Dust: Fine particles can infiltrate the unit, compromising chips and other sensitive electronics.

Freezing water: As water expands, it can exert pressures up to 30,000 psi in small gaps, creating wider openings and structural vulnerabilities.

Weather-resistant material solutions for EVSEs

Exterior sealing – BISCO® HT-800

The exterior seal is your first line of defense against the weather. This silicone foam forms a resilient seal around the enclosure to block water, dust and debris. It maintains compression and elasticity through long-term outdoor use — enduring through hot summers, freezing winters and exposure to UV rays. 

Enclosure venting – DeWAL® DW932 and DW353

Keeping out rain and dust is part of the challenge of protecting inner components from outside elements. Yet, a charging station needs a means to vent heat. These PTFE venting membranes equalize pressure while keeping out contaminants, helping prevent condensation that can damage sensitive electronics.

Interior enclosure seals – PORON® 41 and BISCO® HT-800

It’s also smart to protect components inside the box as an extra layer of protection. Interior seals provide a second layer of protection around connectors and seams, extending reliability in harsh outdoor conditions.

Beyond materials: Converting expertise for a perfect fit 

Protecting your EV charging enclosure from premature weather damage extends performance and uptime — strengthening both your brand and your reputation. To design resilient EV charging enclosures, tap into the expertise of SRP to get it done. 

Rogers brings the portfolio of high-performance foams and sponges engineered to defend your components against the weather. SRP has the advanced tools and skilled machinists to convert them into close-tolerance components that fit and protect. 

Use our handy application finder to identify the right materials and contact one of our experts today.