The rise of electric mobility has accelerated a profound transformation in the automotive industry. And at the heart of this revolution, batteries have become the most critical, complex, and demanding component. Their design poses major technical challenges such as heat dissipation, mechanical protection, electrical insulation, sealing, fire resistance, and compatibility with delicate materials.
Faced with this challenge, manufacturers are looking for solutions. And that’s where Technical foams come in.. These are lightweight, versatile, and highly customizable materials that allow each battery pack to be adapted to specific safety, efficiency, and regulatory requirements.
At ZFoam, we have been working for years with automotive, engineering, and electronics manufacturers to solve these challenges at their root, with materials designed, converted, and assessed to provide real value inside the electric vehicle.
Why are foams key to battery protection and management?
When we talk about lithium-ion or lithium iron phosphate (LFP) batteries, we are talking about energy storage and environments on which temperature, vibration, pressure, and electricity coexist in millimetres of space, with delicate components, which must also perform at their limits for thousands of charge cycles.
Technical foams add value precisely in this area.
- Thermal insulation and temperature management preventing hot spots, stabilizing the thermal environment of the module, and protecting components from critical fluctuations.
- Impact and vibration absorption Key in modules that suffer movement or deformation, foams cushion mechanical stress on the cells.
- Sealing They contain gases, liquids, or particles, preventing leaks or internal interference.
- Chemical and conductive compatibility Specific formulations are available to prevent corrosion, resist electrolytes, or protect against electrostatic discharge (ESD).
Fire retardancy Materials with UL-94 V0 or FMVSS 302 classification provide safety against short circuits or overheating.
In addition, foams can be precisely adapted to complex geometries through die cutting, laminating, or CNC machining.. This facilitates their integration into automated lines or modular modules.
Foam types used in electric vehicle batteries and their function.
The requirements within a battery system are as diverse as their formats. ZFoam works with a complete range of technical foams that can meet a wide variety of requirements, whether in the core of the module, the outer casing, or auxiliary solutions such as connectors, sensors, or control electronics.
Cross-linked polyolefin foams (AZOTE® range)
These are one of the most versatile and widely used solutions in electric mobility. As they are closed-cell foams with a uniform structure, they offer an excellent combination of lightness, thermal insulation, and chemical stability. Their low thermal conductivity helps control the temperature between cells and prevents thermal leakage points.
In addition, they feature
- Very low absorption of water and chemicals
- High compressive strength even in prolonged cycles
- UL 94 HF-1 classification and possibility of V0 formulations
- Density range between 25 and 120 kg/m³
- Possibility of conductive or ESD versions
EVA foams (EVAZOTE® range)
Also, with a closed-cell structure, EVA foams offer greater flexibility and resilience to deformation.. They are ideal for absorbing impacts or vibrations without losing shape or transmitting stress to electronic components.
Technical polyurethane (PU) foams
In its technical version (cross-linked, agglomerated, or filtering), polyurethane becomes an excellent ally for auxiliary applications within the electrical system. Its open structure promotes breathability, filtering, or sound absorption.
Conductive or dissipative foams (SD, CN)
When electrostatic safety is a priority, conductive or dissipative foams prevent unwanted discharges between sensitive components.
Adaptable processes and formats
All these foams can be supplied in sheets, coils, or converted parts ready for integration. Thanks to Foam’s capabilities, it is possible to work with precise tolerances, apply technical adhesives, combine multilayer materials, and design customized solutions from prototype to mass production.
Competitive advantages of ZFoam in battery solutions
In a sector where technical demands are on the rise, the supplier not only provides material, but also responsiveness, industrial reliability, and knowledge of the environment. At ZFoam, we have aligned our offering with the real requirements of those who design, assemble, and certify battery systems.
These are some of our strengths in this area:
- Total adaptability. ZFoam is not limited to one raw material. Our ability to work with multiple ranges of technical foams allows us to offer the most suitable solution for each application.
- Local production, global agility. Located in Zaragoza and with export capacity to more than 25 countries, we combine the flexibility of a local supplier with the structure necessary to support international projects.
- Fast prototyping and internal processes. We have our own machinery for laminating, die-cutting, CNC machining, applying technical adhesives, thermoforming, and other complementary processes.
- Certifications and a culture of industrial quality. We work under ISO 9001, ISO 14001, and CR standard certifications. We are also in the process of obtaining IATF 16949. certification. ZFoam has been evaluated by Ecovadis Certificate Gold Metal and recognized for its performance in sustainability. We also promote an internal culture based on the principles of Lean Manufacturing and 5S methodology, which ensure order, efficiency, and continuous improvement in all our processes.
Expert technical advice. Our team is made up of materials engineers, production technicians, and industrial application specialists.
Application cases and examples of solutions
- Internal separators between cells. In prismatic or cylindrical cell packs, cross-linked polyolefin foams are inserted as a separating element.
- Perimeter insulation and BMS protection. Battery management systems (BMS) require a vibration-free environment that is isolated from thermal or electrical interference. In these situations, selecting the right material can make all the difference, with foams offering low thermal conductivity, sealing capacity, and stable performance in demanding environments.
- Sealing of covers and external encapsulation. ZFoam manufactures foam gaskets for thermal, mechanical, or environmental sealing. This solution is also used in sectors such as rail, where fireproof insulation is crucial to comply with demanding regulations, as explained in this article on insulation in the railway environment.
- Packaging and transport of cells or modules. During transport or internal logistics, battery cells must be protected against impact or discharge.
- Filling material in modular structures. The gaps or spaces between modules, connectors, or auxiliary systems are filled with custom-made foam pieces.
Additional example:
Battery Lid Seal. Based on actual ZFoam projects, special gaskets are designed for the upper closure of the battery module (battery lid). These parts, made of EPDM or closed-cell foam, ensure watertightness, thermal protection, and impact absorption.. They are delivered pre-cut or die-cut according to the customer’s design.
- Additional example: Internal shock absorber. Certain cells require customized cushioning solutions to prevent microfractures caused by vibration.. ZFoam supplies technical foam parts adapted to the internal battery housings. They dissipate energy and prevent displacement.
A technical material with real impact
Designing an efficient battery is not just a matter of chemistry.
It is also a question of materials, engineering, and adaptation.. Technical foams can solve many of the challenges posed by electric vehicles from within: insulation, safety, strength, and flexibility.
At ZFoam, we have been helping manufacturers to incorporate customized solutions into their products for over 20 years. From battery modules to electronic components, our experience allows us to go beyond the material and offer a real answer to every need.
Want to try it for yourself?
If you are developing a new module, need to improve your thermal insulation, or are evaluating options for battery packaging, our team can help.
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