Views: 0 Author: Site Editor Publish Time: 2025-05-14 Origin: Site
How to Select the Right Silicone Foam for EV Battery Modules?
— A Practical Comparison Between Rogers Bisco® HT800 and XYFoam® SSF-T35
In electric vehicle (EV) battery modules and power electronics systems, foam materials are no longer simple fillers—they play a critical role in thermal management, structural support, and safety protection. If a material lacks sufficient compression resilience or thermal stability, it may result in:
Cell displacement and module fatigue damage
Abnormal heat conduction or localized overheating
Seal failure or amplification of vibrations
Reduced system lifespan and increased safety risks
Rogers Bisco® HT800 has long been recognized as a premium silicone foam in the industry, widely used in electric vehicles, rail transit, and more. However, with increasing demands for flexible supply chains, cost optimization, and rapid validation, many companies are now reevaluating their material choices—especially during the transition from prototyping to mass production.
This article aims to help engineers and procurement teams identify the most suitable silicone foam for their application needs, based on real-world performance characteristics.
| Performance Parameter | Rogers Bisco® HT800 | XYFoam® SSF-T35 |
|---|---|---|
| Base Material | Silicone Foam | Silicone Foam |
| Density | 352 kg/m³ | 370 kg/m³ |
| Compression Set (100°C) | ≤5% | ≤5% |
| Compression Force (25% def.) | 62 KPa | 75 KPa |
| Flame Rating | UL94 V0, HF-1 | UL94 V0, HF-1 |
| Thermal Conductivity | 0.09 W/m·K | 0.07 W/m·K |
| Tensile Strength | ≥300 KPa | ≥300 KPa |
| Elongation at Break | ≥80% | ≥80% |
| Operating Temperature Range | -55°C to +200°C | -60°C to +200°C |
| Dielectric Strength | 3.58 kV/mm | ≥3.0 kV/mm |
| Volume Resistivity | ≥10⊃1;⊃3; Ω·cm | ≥10⊃1;⁴ Ω·cm |
Compression Performance & Sealing
With suitable compression stress in the 40%–60% compression range, SSF-T35 provides excellent sealing performance. It is ideal for battery pack covers, service access ports, electrical cabinets, HVAC units, and other applications that require high sealing efficiency.
Lightweight & Space-Conscious Design
This medium-density foam significantly reduces weight compared to traditional solid sealing materials, contributing to the overall lightweighting of the vehicle.
Electrical Insulation & Flame Resistance
Rated UL94 V0 for flame retardancy, and equipped with outstanding volume resistivity and dielectric strength, SSF-T35 plays an important role in the safety management of battery packs.
Temperature Resistance & Environmental Adaptability
Operating reliably between -60°C and +200°C, SSF-T35 performs exceptionally well in low-temperature flexibility tests, making it well-suited for extreme environments.
Supply Chain Responsiveness & Flexible Delivery
We offer fast turnaround and support for low-volume prototyping—perfect for urgent projects or localized supply chain requirements.
✅ When moderate compression force and superior sealing are required
✅ When lower thermal conductivity and higher insulation are priorities
✅ When the application demands a broader operating temperature range, especially in cold conditions
✅ When reducing lead times is critical
✅ When a combination of flame resistance, weatherability, and electrical insulation is needed
We recommend real-world validation based on your specific application. Key performance aspects to assess include:
Compression force and rebound resilience
Long-term thermal stability and aging performance
Electrical insulation and flame resistance
We offer free support, including:
✅ Technical Data Sheets (TDS)
✅ Sample kits
✅ Detailed performance test reports
✅ Direct technical support from our engineers
Download TDS | Request Samples | Contact Us
sales@xyfoams.com
www.xyfoams.com
