Views: 0 Author: Site Editor Publish Time: 2025-06-06 Origin: Site
The root cause may lie in a long-underestimated structural layer—buffer foam.
In thermal runaway management of power battery systems, the interlayer between structural components not only serves for cushioning and positioning but also plays a crucial role in controlling the heat propagation path.
In recent years, with the widespread adoption of CTB (Cell-To-Body) architecture, degraded compression performance of foams has repeatedly emerged in post-project reviews—becoming a critical factor in multiple thermal propagation cases.
The “Short Board Effect” in Thermal Management
Even if the overall structural design is sound, once the cushioning layer collapses under high temperatures, thermal runaway may bypass the intended protection logic and form a penetration pathway.
An ideal gap-filling material should meet the following core performance metrics:
| Property | Technical Index & Significance |
|---|---|
| Compression Set ≤5% | Ensures long-term elastic recovery under high temperature (100°C) |
| Thermal Conductivity ≤0.08 W/m·K | Inhibits heat transfer and delays propagation within modules |
| Compression Stress @25% ≈170 kPa | Provides reliable structural support and cushioning under clamping force |
| Tensile Strength ≥800 kPa | Prevents tearing and breakage; maintains die-cutting and assembly integrity |
| Flame Retardancy UL94 HF-1 / V-0 | Complies with fire protection standards in battery system design |
| Density: 500±50 kg/m³ | Compatible with varied mechanical and thermal demands of module structures |
Good Lab Results but Poor In-Use Performance?
Common engineering issues tend to fall into these categories:
Uncontrolled long-term compression deformation
→ Initially performs well but gradually degrades under heat and load, leading to loose structure.
Material misjudgment: softness ≠ cushioning
→ Foam with insufficient density may feel “soft” but lacks sustained support, failing to maintain tight fit.
Poor dimensional stability affects die-cut precision
→ Inadequate thermal stability or inconsistent internal structure can cause assembly misalignment or cavity formation.
Recommended Material:
SSG-E49 Series | Ceramic-forming Silicone Foam
Tailored for cell thermal runaway buffering, structural insulation, and flame-retardant scenarios.
Key Features:
High-temperature ceramic transformation: Forms self-supporting ceramic skeleton at 450–500°C
Thermal conductivity: 0.08 W/(m·K) for effective insulation
Compression set: 2.8% @100°C, maintains thickness over time
Compression stress @25%: ≈170 kPa, ensuring reliable structure and no collapse
Flame retardancy: UL94 V-0 / HF-1 certified – low smoke, non-dripping, highly fire resistant
-55°C flexibility: Suitable for full-climate use
Density: ~0.5 g/cm³, applicable to various cell structure conditions
Typical Application Scenarios:
Buffering and insulation layer between battery cells to resist thermal runaway
Flame-retardant padding between liquid cooling plates and module bottom structure
Fireproof encapsulation under battery pack covers
Thermal protection barrier between battery modules
Material is not a decoration—it is a defense.
SSG-E49 series has been reliably deployed in power battery systems across multiple countries and supports:
Material matching assessment & selection consultation
Sample provision in multiple thicknesses + die-cutting compatibility
Complete testing reports and compliance certification
Custom structural sizing & volume production
For inquiries, please contact:
sales@xyfoams.com
www.xyfoams.com
