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Rigid Polyurethane Foams for Electric Vehicle (EV) Batteries Advanced Insulation

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Rigid Polyurethane Foams for Electric Vehicle (EV) Batteries Advanced Insulation

Rigid polyurethane foams are carving a niche in the electric vehicle (EV) battery sector, offering an innovative solution to bolster battery safety, thermal management, and structural integrity. Recognized for their exceptional insulation properties, these foams contribute significantly to the overall performance and reliability of EV batteries. As the EV market continues to expand, the role of advanced materials like rigid polyurethane foams in improving battery systems becomes increasingly vital.


These foams stand out for their outstanding thermal insulation capabilities, ensuring that the battery operates within its optimal temperature range. This is crucial for maintaining battery efficiency and longevity, as excessive heat can lead to faster degradation of battery cells. Furthermore, rigid polyurethane foams provide excellent fire resistance, adding an extra layer of safety by reducing the risk of thermal runaway—a condition where one cell's failure can lead to a domino effect, potentially causing a battery fire.



Material Composition

Made from polyurethane (PU) and RPU (rigid polyurethane foam), providing exceptional durability, insulation properties, and support.


Ranges between 470-530 Kg/m⊃3; for PU, ensuring lightweight yet effective insulation. RPU density is optimized for support in water-cooling plates.


Level of 65-70C for PU, offering resilience against physical stresses. RPU hardness is tailored for structural support in water-cooling systems.

Flame Retardant

Rated at a V-0 flammability standard for excellent resistance to fire, applicable to both PU and RPU components.

Impact Resistance

Engineered to withstand stone impacts, protecting the battery pack from external damages. Enhanced by RPU's structural integrity for added protection.

Thermal Conductivity

Exhibits low thermal conductivity (<0.08W/m·K) for PU, enhancing insulation efficiency. RPU's thermal properties support optimal heat dissipation in water-cooling plates.

Tensile Strength

PU boasts a tensile strength of 1-1.5Mpa, showing strong resistance to stretching forces. RPU complements this with high structural strength for water-cooling plate support.

Elongation at Break

PU material stretches 200%-300% of its original length before breaking, indicating flexibility and durability. RPU maintains structural integrity under stress.

Corrosion Resistance

Successfully resists damage from gasoline, acids, and bases, ensuring longevity in harsh conditions for PU. RPU additionally offers enhanced chemical resistance for water-cooling environments.

Recommended Application

Easy application and removal with pressure-sensitive adhesive for PU, ideal for EV battery pack exterior. RPU serves as a supportive water-cooling plate padding, ensuring efficient thermal management and structural support.


In addition to thermal management and fire safety, rigid polyurethane foams enhance the mechanical strength and vibration damping of battery packs. Their structural support helps protect sensitive battery components from mechanical shocks and vibrations during operation, contributing to the battery's durability and performance stability over time.

Our Rigid Polyurethane Foams is a crucial component for EV manufacturers seeking to improve battery safety and performance while adhering to environmental and safety regulations. For more information or to request a sample, please contact our silicone experts.


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