The electric vehicle (EV) market continues to demand fast-charging, crash-safe, and thermally stable battery systems, as well as reliable powertrain components. In response, Covestro has developed a range of material solutions engineered to support these evolving requirements.
The company offers customized polyurethane potting systems under the Baysafe BEF (Battery Encapsulation Foam) product family. These systems are designed for use by OEMs and battery manufacturers to foam high-voltage battery packs.
As electric vehicle (EV) batteries increasingly incorporate numerous fast-charging cells, the need for flame-retardant, impact-resistant, and temperature-stable materials becomes increasingly critical.
Baysafe BEF also provides thermal and electrical barrier properties that help prevent thermal runaway events within the battery. Its excellent adhesion characteristics increase the torsional stiffness of the entire pack, making it well-suited to support structural integrity in cylindrical cell architectures and modern cell-to-pack designs.
Additionally, Covestro’s Bayblend FR polycarbonate and ABS blend addresses these needs by serving as an ideal material for cell holders and battery modules. This lightweight material provides thermal stability at 80° C and meets the UL94 V-0 flame retardancy rating.
For additional structural protection, Makroblend resin delivers the durability required for battery housing, withstanding vibration, impact, and mechanical stress consistent with industry abuse testing.
Key processing benefits of Baysafe BEF include:
- Tailored flow properties for filling tight spaces between battery cells
- Short cycle times due to optimized foam kinetics
- High potential for automated foaming processes
Product benefits include:
- Custom formulations to meet specific customer and product requirements
- Lightweight design and efficient material use
- Encapsulation of cells for protection against mechanical, electrical, and thermal influences
- Strong adhesion to cell casings and battery housing, supporting torsional stiffness in battery packs
- Compatibility with modern cell-to-pack battery architecture designs
Through these solutions, Covestro supports the production of safer, more efficient, and more reliable EV battery storage systems.
Filed Under: Adhesives, Technology News