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As consumer demand for hybrid electric vehicles (EVs) grows, so do requirements for the batteries they contain. Consumers want comfortable, affordable, and safe vehicles capable of high mileage. All of this is possible with new EV battery designs, such as cell-to-pack and cell-to-chassis.
Next-generation batteries need innovative materials, including flame-retardant foams. Flame-retardant foams help mitigate thermal runaway and enable lighter, more powerful, and durable batteries. They also help manufacturers meet changing requirements for battery energy storage systems, electric vertical takeoff and landing equipment, and electric transportation fleets.
Battery manufacturers are no longer questioning whether to use flame-retardant foams, but which foam type is best for their application.
The Right Decision Starts with a Question
Choosing the right flame-retardant foam depends on your battery end-goals. For example, some manufacturers may aim to create a lighter-weight battery by taking out plastic separators and module cases. Others may not need extra support within the battery, but may want a better way to mitigate the risk of thermal runaway.
Navigating the decisions leading to which flame-retardant foam to use is no small task. For help choosing the right flame-retardant foam for your design and application, you can reach out directly to the battery team at H.B. Fuller.
Which Foam is Right for Battery Energy Storage Systems?
Battery energy storage systems (BESS) store energy from renewable sources, such as solar and wind. These energy-dense, stationary units can also convert the direct current stored in batteries into alternating current for use in homes and businesses. BESS units help improve the reliability of new energy sources by dispersing energy to meet demand.
Although all BESS perform similar functions, not all BESS need the same flame-retardant foam because their designs vary widely. Some BESS manufacturers may rely on battery modules to hold the cells in place, while others may need the additional support that structural foams can provide.
Work with the Original Industry Experts
Today, flame-retardant foams are commonly used in electric batteries. It wasn’t always this way, however. H.B. Fuller is the original patent holder for flame-retardant foams with many years of expertise formulating foams to meet customer needs. Partnering with the company that first developed flame-retardant foams and continues to build its product portfolio provides a competitive advantage.
Which Foam Works Best for Electric Vertical Takeoff and Landing Craft Batteries?
Electric vertical takeoff and landing (eVOTL) craft have different battery requirements than BESS. Unlike BESS, eVOTL batteries are not housed in permanent structures and must resist moisture and exposure to harsh chemicals. Lightweighting eVOTL batteries is essential for making (and keeping) craft airborne.
Structural flame-retardant foams, over soft foams, meet eVOTL requirements. Structural flame-retardant foams allow eVOTL battery manufacturers to remove heavy mechanical supports without compromising battery integrity. This greatly reduces battery weight. Foams protect battery cells from the environment and contain thermal runaway to a single cell, mitigating the risk of an event spreading through the battery.
Flame-retardant foams also insulate cells from extreme temperature fluctuations, improving their performance. Consider the external temperature swings eVOTL battery cells endure—from hot tarmac during preparations to bitterly cold temperatures in flight. When in use, internal battery temperatures rise; when not in use, they fall. Flame-retardant foams keep temperature uniform within the battery pack, helping cells operate more efficiently for longer.
Consider UL Flame Ratings for Flame-Retardant Foams
Reducing the potential for thermal propagation is essential for keeping pilots and passengers in eVOTL safe. UL flame classification helps buyers understand how effectively flame-retardant foams reduce the risk of thermal runaway in a battery. The H.B. Fuller EV Protect™ flame-retardant foams are UL-rated to V0 (vertical flammability) and HB (horizontal flammability).
To meet the V0 rating, flame-retardant foams must pass a series of tests. An open flame is held to a piece of foam for 10 seconds, and then the process is repeated. This two-part test is replicated on four additional samples. To pass:
- All samples must stop an open flame within 10 seconds, without dripping
- The total time for all five samples must fall under 50 seconds
This second criterion is critical—to meet V0 standards, samples must extinguish the flame extremely quick, on average, within 5 seconds.
H.B. Fuller offers customers V0 flame-retardant foam, whereas other foam providers typically offer V1-V2-rated foams. Using V0 foam in your eVOTL craft, BESS, or EV is a valuable differentiating factor in these industries.
Which Foam Best Supports Electric Vehicle Batteries?
Consumer interest in hybrid EVs has increased over the past year, while interest in battery EVs has remained unchanged. Concerns include a lack of charging infrastructure and cost. EV manufacturers have responded by shifting their focus to developing hybrid models, with fully battery-powered EVs a future goal.
Increasing battery range is critical to attracting buyers to battery EVs and improving the popularity of hybrid EVs. Also, a higher battery range can help make EV heavy machinery, transportation, and trucking a reality.
To effectively increase battery range, manufacturers must balance energy density with battery weight. Adding more cells to increase energy density creates heavier batteries, which require more energy to move. Finding ways to increase power while keeping weight low is critical to achieving longer ranges.
Next-generation designs can help EV battery manufacturers achieve lightweight, high-energy batteries. Replacing mechanical and plastic components with structural foam removes weight and allows energy-dense designs. Choosing a highly flame-retardant foam also helps prevent excessive heat from leading to thermal runaway in closely spaced cells.
Besides enabling new designs and increasing safety, structural flame-retardant foams benefit EVs by:
- Decreasing manufacturing complexity. Simplified production reduces costs, leading to more affordable vehicles.
- Improving vibration resistance. Bumps are inevitable, but they don’t have to affect battery function and longevity. Structural foams keep vibration from prematurely aging batteries or jolting components out of place.
Choose Partners, Not Just Providers
H.B. Fuller experts work closely with customers to select the flame-retardant foam that best suits their application and implement it on their production line. First, the team discusses customers’ goals to orient the entire process. Then, the team helps customers choose the right flame-retardant foam or customizes formulations if needed, tests products, and optimizes battery-filling procedures.
After implementation, the team communicates with customers to ensure the process works as expected and goals are being met. It’s a collaborative, involved effort.
Not All Foams (and Foam Providers) Are Created Equal
The flame-retardant foam you choose for your BESS, eVOTL, or EV batteries depends on your needs. And picking your foam provider depends on expertise, product performance, and support.
H.B. Fuller offers a wide range of flame-retardant foams to customers across Europe, Asia, and the United States. In the United States, flame-retardant foams include:
- H.B. Fuller EV Protect 4006: Semi-structural foam minimizes battery weight, protects from thermal propagation, and provides noise, vibration, and harshness resistance.
- H.B. Fuller EV Protect 5008: Structural foam with enhanced support. Designed for parts and components in batteries and EVs.
- H.B. Fuller EV Protect 5009: Highly structural foam allowing manufacturers to reduce or replace traditional structural components. Ideal for cell-to-chassis designs.
Contact an H.B. Fuller expert today to discuss which flame-retardant foam best meets your product and production requirements.
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