Battery potting foams

What is battery potting foam?
- Battery potting foam is a liquid-applied material used to surround or protect battery cells and components. It provides thermal protection and insulation while helping manage the effects of thermal runaway.
What is potting foam used for in batteries?
- Potting foam can be used to protect cells and components from extreme heat, flames, hot gases and high-velocity particles during a thermal event. It can also provide insulation and help secure components within the battery assembly.
How does potting foam protect against thermal runaway?
- When exposed to extreme temperatures, the foam forms a protective char that helps resist heat and erosion from high-temperature gases and particles, reducing the risk of damage spreading to surrounding components.
Can potting foam be applied directly to battery cells?
- Yes. Our F4-Series of potting foams can be applied directly to cells and other battery components where required, allowing protection to be formed around the specific geometry of the battery assembly.
How is battery potting foam applied?
- Our range of potting foams are typically supplied as a liquid and applied using mixing and dosing equipment. Its flow characteristics allow it to fill spaces and conform to the shape of the components being protected.
Can potting foam be used for high-volume battery production?
- Yes. AIS' potting foams can be applied using automated mixing and dosing systems, making them suitable for repeatable, scalable manufacturing processes.
Is potting foam lightweight?
- Yes. Potting foams can provide thermal protection at a relatively low weight, making them suitable for applications where minimising additional battery weight is important.
How quickly does potting foam cure?
- Cure time depends on the formulation and application requirements. Fast-curing formulations are available where production processes require a short time between application and handling.
Can potting foam be customised?
- Yes. Potting foam can be formulated and applied to suit different battery designs, protection requirements and manufacturing processes, including different flow, cure and application characteristics.

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Potting foam

Advanced thermal protection for battery packs

AIS' potting foams for battery protection provide lightweight, high-temperature protection for battery cells and components. The low-viscosity, self-levelling formulation can be poured or potted directly into battery assemblies, forming a tough protective char during thermal events that will resist erosion by high velocity or turbulent gasses.

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Benefits

Lightweight protection that works around your design

Our potting foam solutions combine high-temperature protection with a lightweight, self-levelling formulation that can be applied directly to battery components and integrated into scalable manufacturing processes.

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Lightweight, convenient protection

AIS' potting foams have a low density and can be applied in various thicknesses to keep weight to a minimum. Due to their low viscosity, they are well suited to high volume potting processes.

Protect against thermal runaway

When exposed to high temperatures, the foam rapidly forms a tough char that resists erosion from high-velocity or turbulent gases, helping protect surrounding components during a thermal event.

Lightweight protection that fits your battery design

F-Series potting foam combines thermal protection with easy application, helping manufacturers protect battery components without adding unnecessary weight or relying on pre-formed materials.

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