EV/HEV Battery
Pads and Cushions
- UL Compliant
- Excellent Compression
- Force Deflection Properties
- Thermal Prorogation Delay
- Fire Safety
The vast majority of vehicles on the road today are powered by traditional fuels, but make no mistake, electric vehicles (EVs) are making serious inroads. In 2021, 5.7 million EVs were sold globally. Slowly but surely, personal transportation is becoming more reliant on electricity. As a result, EV batteries have to provide more power, more cycles and a longer lifetime if EVs are to ever truly flourish. Lithium-ion (Li-ion) battery packs remain the go-to power source for the EV industry due to their impressive power density and charging efficiency.
Lithium-ion (Li-ion) batteries require cushioning, sealing and vibration isolation that must perform reliably under tough conditions. These conditions raise an array of challenges for designers to overcome such as Thermal runaway, battery pack safety, fire safety and the batteries range extension to name but a few.
CB Frost have teamed up with Rogers’ Corporation and their range of materials as they suite a variety of battery pad solutions and are designed to provide designers with high-performance options that can withstand the stresses of fluctuating compression and temperature. PORON® polyurethanes and BISCO® silicone materials are designed to reliably hold a consistent force, keeping battery cells aligned, sealed from dust and fluid and isolated from the damaging effects of vibration.
CB Frost's range of material offers the
following key attributes
Excellent Fire Retardancy
Low Outgassing
Excellent Compression Set Resistance
Good Chemical Resistance
Meets Several Flammability Requirements
Thermal Prorogation Delay
Capacity Fade Reduction
Pressure Management Pads
Pouch Cell Pads - Increasing efficiency and lifetime PORON® polyurethanes pouch cell pads hold components in place while withstanding dimensional changes to the pouch cells over the life of the battery. In parallel, they protect the cells against internal impact and vibration.
Battery Housing Seals
Battery Housing Seal - Protecting the battery in all environments.
BISCO® silicones provide ingress protection over the lifetime of the battery pack.
Cooling Plate Spring Pads
Cooling Plate Spring Pads – Maintaining resiliency for consistent cooling performance.
BISCO® silicones and PORON® polyurethanes are used as reliable elastomeric springs to maintain close contact between the cooling plate and the battery, ensuring performance.
Thermal Runaway Protection Pads
Thermal runaway - a cycle in which excessive heat keeps creating more heat.
BISCO® materials are widely used as a solution. These range of materials not only seal effectively, but also offer fire protection as it has excellent resistance to high and low temperatures and is also UL94-V0 compliant.
Manual Service Disconnect Seals
Manual Service Disconnect Seal – Sealing for safety
BISCO® silicones are used as reliable environmental seals that withstand repeated open ing and closing, extreme temperature swings, and other environmental factors. The materials’ flame resistance (UL-V0) also contributes to the safety requirements for high voltage batteries.
Anti Vibration Pads
PORON® polyurethane and BISCO® silicone anti-vibration pads are proven solutions within the automotive industry, providing solutions as vibration dampeners and isolators. The C-set (Compression Set) of these unique materials withstands collapse caused by the stresses of compression and temperature over time, extending the life of the battery by continuing to seal and absorb shock.
Cushioning Pads
Battery pads made from PORON® polyurethane and BISCO® silicone foams have a unique ability to produce a very consistent level of force across a range of compressions. PORON® material pads and silicone battery compression pads enable the designer to predict the material’s behaviour across varied dimensional tolerances.
Available/Suitable Materials Include
Poron Polyurethane
EVExtend Polyurethane
BF2000 Silicone Foam
HT800 Silicone Foam
BF1000 Silicone Foam
ProCell Aluminium Foil
| Application | Material | Benefits |
|---|---|---|
| Cell-to-Cell Compression Pad / Separator Insulation | PORON EVExtend® Material Optimal Pressure with Usable Range 4790-92 (Extra Soft, Slow Rebound) 4701-50 (Firm) V0 (Flame Retardant) |
|
| Thermal Propagation Protection | PORON EVExtend® Material ProCell™ EV Firewall Material 350 |
|
| Battery Pack Seal | BISCO® Silicone Material HT Series Flame Retardant, Gasketing, Water Sealing Medium to Firm Grade |
|
| Cooling Plate Cushion Pad | BISCO® Silicone Material HT Series Consistent Push-back Force over Vehicle Life Medium to Firm Grade |
|
| Environmental Sealing, Insulation | BISCO® Silicone Material HT Series Flame Retardant, Gasketing, Water Sealing Medium to Firm Grade |
|
| PORON® AquaPro® 37/41 Soft, Enhanced Sealability |
|
|
| Battery Management System Spring Pad and Gasket for Sensors and Flexible Printed Circuit Boards | PORON EVExtend® Material BISCO® Silicone Material HT-800 (Medium Firm) HT-870 (Medium) |
|
| Burst Vent | DeWAL® Venting Material DW232PA |
|
| Pressure Equalization & Protection | DeWAL® Venting Material DW930 Series |
|
Common Applications
Battery Compression Pads and Cushions
Battery Pad cushions, or compression pads, used inside an EV pouch cell battery pack must be firm enough to hold components in place and compressible enough to withstand dimensional changes to the pouch cells over the life of the battery. Reliable compression set resistance (C-set) and stress relaxation performance over a broad range of temperatures and conditions is critical. Battery pads made from PORON® polyurethane and BISCO® silicone foams have a unique ability to produce a very consistent level of force across a range of compressions. PORON® material pads and silicone battery compression pads enable the designer to predict the material’s behaviour across varied dimensional tolerances.
Anti-Vibration Pads for Vibration Isolation
Batteries also need to be packaged to absorb internal impact energy. Vibration must be managed both within the pack and between the pack and the vehicle. PORON polyurethane and BISCO silicone anti-vibration pads are proven solutions within the automotive industry, providing solutions as vibration dampeners and isolators. The C-set of these unique materials withstands possible collapses caused by the stresses of compression and temperature over time, extending the life of the battery by continuing to seal and absorb shock.
Battery Enclosure Sealing and Fastening
BISCO® silicone foams are the solution of choice for sealing and protecting battery enclosures from potential damage caused by the elements and road debris. Gaskets fabricated from BISCO® silicone material seal out water, dust and debris while providing exceptional temperature and UV resistance. PORON® polyurethane material is designed to reliably hold a consistent force, keeping battery cells aligned, sealed from dust and fluid and isolated from the damaging effects of vibration.
Thermal Runaway
The term thermal runaway is used when the chemistry in the cells becomes unstable, often due to a charging fault or physical damage. When this occurs, it is catastrophic in terms of heat and pressure. BISCO® silicones have excellent flammability properties help delay the burn from one cell to another.
Key Battery and Energy
Terms to Know
Seals & Gaskets
Seal battery packs, battery modules, and battery covers against temperature impact, air, dust and water ingress. Optimise performance, waterproof and seal while considering compression set and force deflection, NVH (noise, vibration and harshness) and other mechanical factors.
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