Empowering Electric Vehicle Battery Performance with Advanced Foam Technologies

In the rapidly advancing world of electric vehicles (EVs), the quest for enhanced battery performance, safety, and reliability is paramount. 

The Critical Role of Foam in EV Battery Packs

Foam materials are integral to the construction and operation of EV battery packs. They serve multiple purposes, including sealing, vibration damping, thermal management, and structural support.

Sealing Gaskets: The First Line of Defense

Sealing gaskets (A) are essential for maintaining the integrity of the battery pack by preventing the ingress of moisture and contaminants. The PORON® ATR-32 is designed to offer a reworkable and reliable sealing performance at higher temperatures, ensuring the longevity of the battery pack.

Module Spacer Pads: Structural Stability

Module spacer pads (B) provide the necessary support to the battery cells, ensuring structural stability. The CELDAMPER® BF-300 boasts superior vibration damping performance, available in soft to firm grades to accommodate various case shapes, thereby enhancing the overall durability of the battery pack.

Pressure Release Duct Seals: Managing Thermal Dynamics

Pressure release duct seals (C) are crucial for managing the thermal expansion and contraction of the battery pack. The PORON® ATR-32PR delivers sealing performance at low compression, allowing for flexible parts shape design and contributing to the pack's resilience against thermal stress.

Cell Compression Pads / Thermal Runaway Barrier Pads: Safety and Support

Cell compression pads (D) and thermal runaway barrier pads are designed to provide stable compression force to absorb the expansion and contraction of cells. The PORON® XRS-48, XSA-20PR, RX-32, TR-32, and GOM® SPOR® TT-4106, along with the NanNex® TL3503, offer a tacky surface finish that adheres to cells without the need for adhesives, ensuring a secure fit and added safety.

FPC Protection Pads: Preserving Delicate Connections

FPC protection pads (E) are vital for safeguarding the flexible printed circuit connections within the battery pack. The PORON® RX-32 provides vibration protection and resistance to high temperatures and flammability, thereby preserving the integrity of these delicate connections.

Thermal Interface Sheets: Optimal Heat Transfer

Thermal interface sheets (F) play a pivotal role in facilitating heat transfer between the cells and the cooling plate. The Transcool GNS, GXIII materials improve cooling efficiency and thermal management, ensuring that the battery pack operates within optimal temperature ranges.

Cooling Plate Damper Pads: Enhancing Cooling Efficiency

Cooling plate damper pads (G) are designed to enhance the cooling system's efficiency. The PORON® TR-24, CELDAMPER® BF-150, and GOM® SPOR® E-4088, E-4348 offer superior vibration damping performance and stable compression force, minimizing the contact area to cells and improving cooling efficiency.

Module Case Gaskets: Protecting Against Environmental Factors

Module case gaskets (H) serve as the final barrier against dust and water penetration. The NanNex® TL7404 protects the battery pack at low compression force and offers flexibility in case shape design, ensuring that the pack remains secure and functional in various environmental conditions.