Huntsman, a global manufacturer and marketer of specialty chemicals, has added to the company’s battery solutions portfolio a series of new lightweight, durable polyurethane foam technologies developed for the potting and fixation of cells mounted in electric vehicle (EV) batteries.

The new range also includes products that can be used as a moldable encapsulant in battery modules or packs.

The new SHOKLESS foam systems can offer a flexible choice for helping to safeguard the structural integrity of EV batteries in case of impact or a thermal event. The product family includes a range of low to high density foams that can be used via common polyurethane dispensing processes and can offer a wide processing window for extra handling flexibility.

These new solutions can help provide thermal as well as structural protection at a cell, module, or pack level combined with fast processability compared to non-polyurethane alternatives, Huntsman says. The moldable encapsulant version of the SHOKLESS system can further expand design and manufacturing options for EV battery manufacturers and OEMs.

With robust mechanical properties, the new SHOKLESS systems can offer very good compression and tensile performance with high elongation to failure. Elastic performance can remain stable at different operating temperatures ranging from -35 ºC to 80 ºC. The new systems have also been developed to be easy to work with due to their low viscosity and ability to cure quickly at low temperatures.

SHOKLESS polyurethane systems are generally compatible with a number of different manufacturing methods such as open- and closed-pour (injection) and cold-cure molding. Certain products in the range can also be dispensed with high pressure equipment. Huntsman also offers simulation and modeling capabilities that can help customers customize and optimize processing parameters, and the structural and thermal performance of the materials.

Huntsman is a global leader in MDI (Methylene diphenyl diisocyanate)-based polyurethanes, serving automotive customers along the value chain. Huntsman delivers innovative, value-added solutions to the world’s best-known car brands. Specialisms include lightweight, enhanced comfort and working towards sustainability ambitions in seating, interior trim, acoustic insulation, EV batteries and composite panel applications.