{"id":10979,"date":"2025-08-04T10:20:15","date_gmt":"2025-08-04T08:20:15","guid":{"rendered":"https:\/\/www.zfoam.com\/choosing-high-performance-foams-for-e-mobility\/"},"modified":"2025-08-04T10:20:15","modified_gmt":"2025-08-04T08:20:15","slug":"choosing-high-performance-foams-for-e-mobility","status":"publish","type":"post","link":"https:\/\/www.zfoam.com\/en\/choosing-high-performance-foams-for-e-mobility\/","title":{"rendered":"Choosing high-performance foams for E-Mobility"},"content":{"rendered":"<p><span style=\"font-weight: 400;\">The battery is the new backbone of electric vehicles, and within it, foams play a discreet but decisive role. They seal, insulate, support and dissipate heat.  <\/span><span style=\"font-weight: 400;\">But would you know how to choose the right foam to avoid unexpected costs, delays or approval issues?<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">Regulatory context in Spain<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">The UNE 0062 standard and PERTE VEC II subsidies require proof of passive safety and traceability of polymeric materials used in electric vehicles manufactured in Spain. Selecting foams that meet these requirements avoids last-minute redesigns and speeds up the process of obtaining subsidies. <\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span style=\"font-weight: 400;\">1 Set the goal before the technical data sheet<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">A foam is selected when engineering, quality control and purchasing share the same priority. Before opening a technical data sheet, the risk to be avoided and the expected benefit must be put on the table <\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>The risk to be neutralised:<\/b><span style=\"font-weight: 400;\"> cell-to-cell heat propagation, vibrations that loosen joints, electrolyte infiltration, etc.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>The advantage to be achieved<\/b><span style=\"font-weight: 400;\">: lighten 8 kg to gain autonomy, reduce<\/span><i><span style=\"font-weight: 400;\"> time to validation<\/span><\/i><span style=\"font-weight: 400;\"> or add ESG points&#8230;<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">If the most feared scenario is a thermal leak in &lt; 90 s, the priority will be a BISCO\u00ae UL 94 V 0 silicone capable of withstanding 200 \u00b0C. If weight is the main issue, moulded EPP is the natural choice. <\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span style=\"font-weight: 400;\">Quick visual overview<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">As tables can be confusing, it is best to refer to the following<\/span><b> heat map,<\/b><span style=\"font-weight: 400;\"> which summarises at a glance which foam dominates in each property<\/span>:<\/p>\n<p><img decoding=\"async\" class=\"size-fusion-600 wp-image-10957 alignnone\" src=\"https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-600x410.png\" alt=\"Properties of foams\n\n \n\n&#8221; width=&#8221;600&#8243; height=&#8221;410&#8243; srcset=\"https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-200x137.png 200w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-300x205.png 300w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-400x273.png 400w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-600x410.png 600w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-768x525.png 768w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-800x546.png 800w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1-1024x699.png 1024w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/heatmap_propiedades_espumas-1.png 1142w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/><\/p>\n<p><i><span style=\"font-weight: 400;\">*Express glossary<\/span><\/i><span style=\"font-weight: 400;\">:<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><b>Compression set<\/b><span style=\"font-weight: 400;\"> (permanent deformation) = loss of thickness after compression and ageing.<\/span><span style=\"font-weight: 400;\"><br \/>\n<\/span><b>Closed-cell<\/b><span style=\"font-weight: 400;\"> = structure impermeable to water and gases.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span style=\"font-weight: 400;\">3 The \u2018character\u2019 of each family<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Each technical foam has unique properties that make it ideal for certain scenarios and less suitable for others. This brief description will help you quickly recognise which one best suits your specific application <\/span><\/p>\n<table style=\"height: 539px;\" width=\"1096\">\n<thead>\n<tr>\n<th><b>Family<\/b><\/th>\n<th><b>Strengths<\/b><\/th>\n<th><b>Weaknesses<\/b><\/th>\n<th><b>Typical application<\/b><\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><b>Silicone<\/b><\/p>\n<p><span style=\"font-weight: 400;\">(BISCO\u00ae HT-800, PORON\u00ae EVExtend)<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Withstands temperatures from -60 \u00b0C to +200 \u00b0C, UL 94 V-0,<\/span><i><span style=\"font-weight: 400;\"> compression set <\/span><\/i><span style=\"font-weight: 400;\">&lt; 5%, semi-closed microcell, good resistance to glycol-water refrigerants.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">High density and cost.<\/span><\/td>\n<td><i><span style=\"font-weight: 400;\">Gap-filler <\/span><\/i><span style=\"font-weight: 400;\">heat sink under 4680 cells<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>Polyurethane (PU)<\/b><\/p>\n<p><span style=\"font-weight: 400;\">(ZF-EV 45-120 kg\/m\u00b3 formulations)<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Flexible, easy to cut, moderate cost, acceptable chemical resistance to refrigerants.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Ageing &gt; 110 \u00b0C; flammable without additives.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Battery cover seals.<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>Polyethylene\/EVA<\/b><\/p>\n<p><span style=\"font-weight: 400;\">(EVA copolymers for high resilience)<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Very lightweight, closed cell, good dielectric, water absorption &lt; 1%.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">UL 94 HB;<\/span><i><span style=\"font-weight: 400;\"> compression set<\/span><\/i><span style=\"font-weight: 400;\"> &gt; 12%.<\/span><\/td>\n<td><i><span style=\"font-weight: 400;\">Cushion pads<\/span><\/i><span style=\"font-weight: 400;\"> between <\/span><i><span style=\"font-weight: 400;\">pouch cells<\/span><\/i><span style=\"font-weight: 400;\">.<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>PVDF<\/b><\/p>\n<p><span style=\"font-weight: 400;\">(Solef\u00ae cross-linked PVDF)<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Inert to electrolyte carbonates, UL 94 V-0, high dielectric strengh.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Expensive, medium-high density.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Seals on cold plates with electrolyte contact.<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>EPP<\/b><\/td>\n<td><span style=\"font-weight: 400;\">Ultra-lightweight, shock-absorbing, 3-D moulded.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Thermal limit 110 \u00b0C; UL 94 HB.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Structural spacers in cylindrical modules.<\/span><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><b>* Quick note on closed cells<\/b><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">The PE\/EVA and BISCO\u00ae silicone families have a <\/span><i><span style=\"font-weight: 400;\">closed-cell <\/span><\/i><span style=\"font-weight: 400;\">structure, limiting liquid absorption and increasing dimensional stability.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span style=\"font-weight: 400;\">4 360\u00b0 view of performance<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">To see at a glance the balance between conductivity, deformation, density, temperature range and fire behaviour:<\/span><\/p>\n<p><img decoding=\"async\" class=\"size-fusion-600 wp-image-10961 alignnone\" src=\"https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/radar_comparativa_espumas-1-1-600x464.png\" alt=\"Comparison of foams for EVs\" width=\"600\" height=\"464\" srcset=\"https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/radar_comparativa_espumas-1-1-200x155.png 200w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/radar_comparativa_espumas-1-1-300x232.png 300w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/radar_comparativa_espumas-1-1-400x309.png 400w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/radar_comparativa_espumas-1-1-600x464.png 600w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/radar_comparativa_espumas-1-1-768x593.png 768w, https:\/\/www.zfoam.com\/wp-content\/uploads\/2025\/07\/radar_comparativa_espumas-1-1.png 800w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/><\/p>\n<p>&nbsp;<\/p>\n<h2><span style=\"font-weight: 400;\">5 Step-by-step methodology<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Choosing a foam is easier if you follow a structured process. Here are five practical steps to choose the most suitable material for your application scenario and specific requirements. <\/span><\/p>\n<ol>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Failure scenario<\/b><span style=\"font-weight: 400;\">. Identifying the most critical threat (e.g., thermal propagation).<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Weigh criteria<\/b><span style=\"font-weight: 400;\"> (1-5) according to impact on safety and warranty cost.<\/span><\/li>\n<\/ol>\n<p>&nbsp;<\/p>\n<table style=\"height: 360px;\" width=\"706\">\n<thead>\n<tr>\n<th><b>Criterion<\/b><\/th>\n<th><b>Weight <\/b><b><i>(pouch module<\/i><\/b><b>)<\/b><\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><span style=\"font-weight: 400;\">Fire safety UL 94<\/span><\/td>\n<td><span style=\"font-weight: 400;\">5<\/span><\/td>\n<\/tr>\n<tr>\n<td><span style=\"font-weight: 400;\">Thermal conductivity<\/span><\/td>\n<td><span style=\"font-weight: 400;\">4<\/span><\/td>\n<\/tr>\n<tr>\n<td><span style=\"font-weight: 400;\">Chemical resistance <\/span><\/td>\n<td><span style=\"font-weight: 400;\">3<\/span><\/td>\n<\/tr>\n<tr>\n<td><span style=\"font-weight: 400;\">Cost \u20ac\/m\u00b2 <\/span><\/td>\n<td><span style=\"font-weight: 400;\">2<\/span><\/td>\n<\/tr>\n<tr>\n<td><span style=\"font-weight: 400;\">NVH (noise and vibration)<\/span><\/td>\n<td><span style=\"font-weight: 400;\">1<\/span><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<ol>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Filtering standards<\/b><span style=\"font-weight: 400;\">. If the pack specification requires UL 94 V-0, discard all HB families from the outset, thus saving days of development.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Prototype and validate<\/b><span style=\"font-weight: 400;\"> in a controlled environment<\/span>\n<ol>\n<li style=\"font-weight: 400;\" aria-level=\"2\"><b>Thermal cycle <\/b><span style=\"font-weight: 400;\">\u201340 \/ +85 \u00b0C, 96 h at 50% compression.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"2\"><b>Chemical test<\/b><span style=\"font-weight: 400;\"> 72 hours immersion in electrolyte (EC + DEC) at 60 \u00b0C.<\/span><\/li>\n<\/ol>\n<\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Align areas<\/b><span style=\"font-weight: 400;\">. Select the foam that best reduces the relative risk.<\/span><\/li>\n<\/ol>\n<p><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">Reducing the module temperature by 5 \u00b0C extends the service life of the cells by \u2248 10%, reducing incidents.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span style=\"font-weight: 400;\">6 Good integration practices<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">The final effectiveness of the foam also depends on how it is integrated into the battery pack. Below are some practical recommendations for optimising this integration in production. <\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Low VOC<\/b><span style=\"font-weight: 400;\"> adhesive: acrylic laminate &lt;5 g VOC\/m\u00b2.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Zero gaps tolerance<\/b><span style=\"font-weight: 400;\">: joints \u2264 0.2 mm to prevent <\/span><i><span style=\"font-weight: 400;\">rattling<\/span><\/i><span style=\"font-weight: 400;\"> and leaks.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Fluid TIM + silicone<\/b><span style=\"font-weight: 400;\">: ideal duo with cold plate.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Residual compression tests<\/b><span style=\"font-weight: 400;\">: \u2265 60% after 100 lid opening cycles.<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">The final performance of the foam depends as much on its formulation as on <\/span><b>how<\/b><span style=\"font-weight: 400;\"> it is incorporated into the pack. Going beyond the basic tips, this table provides some guidelines: <\/span><\/p>\n<p>&nbsp;<\/p>\n<table style=\"height: 507px;\" width=\"1131\">\n<thead>\n<tr>\n<th><b>Step<\/b><\/th>\n<th><b>ZFoam Recommendation<\/b><\/th>\n<th><b>Benefit<\/b><\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><b>Cleaning and conditioning<\/b><\/td>\n<td><span style=\"font-weight: 400;\">Isopropanol 70% + degassed for 30 minutes at 50\u00b0C in machined aluminium.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Constant adhesion; no delamination.<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>Adhesive<\/b><\/td>\n<td><span style=\"font-weight: 400;\">Acrylic PSA &lt; 5 g VOC m\u00b2 for REACH projects; hot-melt PUR if you need \u2265 2 N cm\u207b\u00b9 at 85 \u00b0C.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Quick installation without compromising peelability.<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>Joint design<\/b><\/td>\n<td><span style=\"font-weight: 400;\">Target compression: 30-40% in silicone, 45-50% in EPP; radii \u2265 1 mm in corners.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Maintains IP-67 and prevents buckling.<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>Zero gap control<\/b><\/td>\n<td><span style=\"font-weight: 400;\">Optical verification of critical thicknesses \u2264 0.2 mm; EVA wedges in gaps.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Eliminates dust\/water entry points<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>Thermal compatibility<\/b><\/td>\n<td><span style=\"font-weight: 400;\">Conductive silicone (Shore 00 30-45) + TIM fluid on cold plate.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">\u0394T edge-cell \u2193 \u2265 3 \u00b0C compared to TIM alone.<\/span><\/td>\n<\/tr>\n<tr>\n<td><b>Residual compression<\/b><\/td>\n<td><span style=\"font-weight: 400;\">Target \u2265 60% after 100 lid opening cycles.<\/span><\/td>\n<td><span style=\"font-weight: 400;\">Guarantees sealing throughout service life.<\/span><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><b>*Quick rule<\/b><span style=\"font-weight: 400;\"><br \/>\n<\/span><span style=\"font-weight: 400;\">For packs subjected to harmonic vibration &gt; 12 g, design the foam to work at 35% of its original thickness, so that it absorbs energy without premature fatigue.<\/span><\/p>\n<p>&nbsp;<\/p>\n<h2><span style=\"font-weight: 400;\">The foam that determines the result<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Choosing the right foam is no small matter. Ultimately, it all comes down to finding the right balance between safety, cost and sustainability: <\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Extreme safety<\/b><span style=\"font-weight: 400;\"> \u2014 BISCO\u00ae \/ PORON\u00ae silicone, PVDF\u00ae, Zotek N\u00ae, Zotek F\u00ae.<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Cost &amp; acoustics<\/b><span style=\"font-weight: 400;\"> \u2014 PU, Azote\u00ae<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Structural lightness<\/b><span style=\"font-weight: 400;\"> \u2014 moulded EPP.<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Can we help you make that decision?<\/span><a href=\"https:\/\/www.zfoam.com\/en\/contact\/\"><b> Contact us<\/b><\/a><span style=\"font-weight: 400;\">.<\/span><\/p>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>The battery is the new backbone of electric vehicles, and within it, foams play a discreet but decisive role. They seal, insulate, support and dissipate heat. But would you know how to choose the right foam to avoid unexpected costs, [&hellip;]<\/p>\n","protected":false},"author":3,"featured_media":10967,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[34],"tags":[],"class_list":["post-10979","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-foams-en"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Choosing high-performance foams for E-Mobility - ZFoam<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.zfoam.com\/en\/choosing-high-performance-foams-for-e-mobility\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Choosing high-performance foams for E-Mobility - ZFoam\" \/>\n<meta property=\"og:description\" content=\"The battery is the new backbone of electric vehicles, and within it, foams play a discreet but decisive role. 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