Encapsulation of cylindrical battery cells with foams

The increasing power density of batteries requires effective heat dissipation to prevent excessive heat generation. By filling the cavities between the battery cells with special foam material, we minimize the risk of overheating. This reduces thermal spread, thus improving heat management and creating a safer environment for drivers and passengers.

Electric vehicles are exposed to various harsh conditions, including shocks and vibrations on uneven roads. Foam encapsulation provides effective damping to protect battery cells from such mechanical stresses. Precise dispensing and application of the foam increases shock resistance and improves the mechanical stability of the battery module, which ultimately ensures the reliability and safety of the vehicle.

Over time, lithium-ion batteries are subject to expansion, which can lead to mechanical interference between the cells. Foam encapsulation ensures that the individual cells are evenly distributed within a module. The cells are reliably separated from each other by the foam. This minimizes the risk of unintentional mechanical stress, which can lead to interference and extends the service life of the battery, which improves the performance of your electric vehicles.

In addition to the material selection, precise dispensing and the processing procedure are decisive for effective foam encapsulation. Process development takes place in our Technology Center to adapt the parameters of the dispensing to the material, your component and the desired process parameters such as cycle times, etc. Our proven approach ensures homogeneous material mixing and prevents undesirable consequences such as uneven foam or damage to the battery module.