EV Battery Foam Solutions for Sealing, Insulation & Cushioning

Finding the right foam material for EV battery systems is critical for performance, safety, and durability.

We provide engineered foam solutions for key battery applications, including sealing, thermal insulation, gap filling, and vibration protection — widely used in EV projects across Thailand and Europe.

Battery Pack Sealing Foam

Applications: battery enclosure, service covers, connectors

Reliable sealing materials are required to ensure:

• Long-term compression performance

• Resistance to heat and environmental exposure

• Stable IP protection

Recommended materials:

• Crosslinked polyolefin foam (IXPE / IXPP)
  → Closed-cell structure, lightweight, excellent sealing performance

Gap Filling & Module Cushioning

Applications: between modules, module to housing, top cover buffering

Foam materials are used to:

• Fill structural gaps

• Absorb vibration and shock

• Improve assembly tolerance

Recommended materials:

• Microcellular PU foam → high conformability

• IXPE foam → stable cushioning & lightweight

Thermal Insulation for EV Batteries

Applications: between cells, module layers, pack interior

Thermal insulation materials help:

• Reduce heat transfer

• Improve system stability

• Delay thermal propagation

Recommended materials:

• Modified polyolefin foam

• Silicone foam for high-temperature zones

Cooling Plate Support

Applications: under liquid cooling plates

Support materials must provide:

• Uniform load distribution

• Elastic recovery

• Long-term mechanical stability

Recommended materials:

• High-resilience PU foam

• Engineered IXPE foam

Flame Retardant & Fire Protection

Applications: cell isolation, high-risk thermal zones

Materials are designed to meet:

• Flame retardant requirements

• High-temperature resistance

• Safety compliance for EV systems

Recommended materials:

• Silicone foam

• Flame-retardant engineered foams

Lightweight Foam Solutions

Applications: weight reduction in battery systems

Advanced foaming technologies enable:

• Lower density

• Energy absorption

• Improved efficiency

Recommended materials:

• Supercritical foamed TPU / TPEE / PP

Looking for the Right Material for Your EV Battery Project?

We support OEMs, Tier 1 suppliers, and converters with:

• Material selection based on application

• Custom specifications (density, thickness, hardness)

• Stable supply for mass production

Feel free to share your project requirements — we can recommend the most suitable foam solution.