Thermal Management and Sealing in EV Battery Packs – Silicone Foam
News
November 11, 2026
The electric vehicle (EV) market is accelerating at a rapid pace as governments around the world introduce strict regulations and legal mandates aimed at drastically reducing greenhouse gas emissions. As personal transportation becomes increasingly reliant on electricity, the demands on EV battery packs are higher than ever. To ensure electric...
The electric vehicle (EV) market is accelerating at a rapid pace as governments around the world introduce strict regulations and legal mandates aimed at drastically reducing greenhouse gas emissions. As personal transportation becomes increasingly reliant on electricity, the demands on EV battery packs are higher than ever. To ensure electric vehicles deliver maximum range, safety, and longevity, engineers are faced with strict requirements for Lithium-ion battery enclosures.
What Are Two of the Most Critical Challenges for EV Battery Packs?
Two of the most important challenges for EV batteries are thermal runaway protection and robust weather sealing.
Many standard insulation materials cannot withstand the harsh environments within an EV battery pack. This is why silicone foam materials have become the go to for EV battery pads, enclosure seals, and vibration isolators.
Why Do Standard Rubbers Fall Short?
Lithium-ion batteries are highly sensitive, requiring robust cushioning, vibration isolation, and complete protection from dust and moisture. Standard commercial rubbers, along with standard Nitrile and Neoprene rubbers struggle with extreme temperature fluctuations, leading to structural degradation, poor compression set resistance, and failure over the lifespan of a vehicle.
In contrast, specialised cellular silicone foams such as BF1000, BF2000, HT800 possess a unique ability to produce a very consistent level of force across a wide range of compressions, whilst withstanding temperatures as low as -55℃ and as high as +200℃. They maintain their structural integrity, ensuring that battery cells stay perfectly aligned, safely sealed, and isolated from the effects of road shock and vibration.
Defending Against Thermal Runaway
One of the biggest safety concerns in EV battery design is thermal runaway, the dangerous cycle where unstable cell chemistry creates excessive heat, potentially spreading rapidly from one cell to another.
High performance silicone materials such as HT800, BF1000 and BF2000 from the Rogers Corporation BISCO® range are engineered to combat this. With their temperature resistant qualities and sealing capabilities, they act as a barrier to provide excellent thermal propagation delay. This helps to contain extreme heat and pressure. These high performance silicone foams are also UL94-V0 compliant, providing the flame retardancy needed for high voltage EV battery enclosures.
Silicone Foam vs Standard Commercial Rubber in EV Applications
To understand why silicone foams are the industry standard for EV thermal management, cushioning, and vibration isolation, we should consider their fundamental properties compared to other insulation materials.
| Material Property | High-Performance Silicone Foam | Standard Commercial Rubber Equivalents |
| Temperature Resistance | Strong, performing reliably in extreme heat and sub-zero conditions (-55℃/+200℃) | Suitable for moderate temperatures, but prone to cracking or melting at extremes |
| Compression Set | Maintains original shape and push-back force over time | Permanently deforms under continuous stress |
| Thermal Runaway Protection | High (UL94-V0 compliant, delaying thermal propagation) | Low (often highly flammable without toxic additives) |
| Environmental Sealing | Blocks moisture, dust, UV and chemicals | Degrades upon prolonged environmental exposure |
The Core Benefits for EV Battery Packs
For automotive designs looking to optimise performance and safety, integrating specialist cellular silicone foam gaskets provides clear, measurable advantages for battery compression pads and cushions, anti-vibration pads, battery enclosure seals, and thermal runaway:
- Vibration Dampening: Absorbs internal impact energy and road vibration to prolong the battery’s operational lifetime.
- Predictability: Enables designers to accurately predict material performance across different dimensional tolerances.
- Safety Assurance: Meets strict automotive and EV flammability and low-outgassing requirements.
- Cooling: Acts as an elastomeric spring to maintain close contact between battery cells and cooling plates.
CB Frost Battery Pad Solutions
As EV continue to be more prevalent on the roads, the need to protect sensitive lithium-ion cells from moisture, vibration and heat is vital. Specifically-engineered materials are needed to guarantee the safety and efficiency required by modern electric cars. By specifying premium silicone foam materials, EV manufacturers can dramatically improve battery pack safety and extend their lifespan.
At CB Frost, we have teamed up with our longtime partner Rogers Corporation to deliver bespoke anti-vibration and thermal management solutions for the EV/HEV sector. With Rogers Corporation’s expertise in high-performance cellular silicones and our precision gasket manufacturing capabilities, we ensure your battery enclosures are sealed and secured, ready for the road ahead.
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