Power Meets Protection with Evonik’s Advanced Froth Foam Additives for Battery Pads
Froth foam padding is essential for extending battery life and enhancing safety across all battery systems, managing two critical functions: mechanical protection and thermal regulation, especially in demanding applications like electric vehicles (EV).
Foam ensures mechanical protection by providing essential shock absorption, vibration damping, and sealing to prevent physical damage to battery cells and internal components— critical for structural integrity and extended lifespan. Foam delivers thermal regulation by acting as an insulator, slowing heat propagation to mitigate thermal runaway, while supporting the flame resistance of the finished pad.
Compression pads also support safety, performance, and longevity by managing cell expansion and contraction during charge/discharge cycles, maintaining consistent electrical contact and isolating sensitive components for reliable operation.
Evonik is your trusted partner for advanced polyurethane additives. Our portfolio includes innovative silicone surfactants, delayed-action catalysts, and dispersants that enable stable, easy to control systems, optimized curing profiles, and higher loading of flame-retardant fillers such as ATH without the viscosity penalty.
Why Choose Evonik for Froth Foam Battery Cushion Pads?
- Proven Expertise: Leading brands such as TEGOSTAB®, POLYCAT®, ORTEGOL® and DABCO® deliver reliable performance in demanding polyurethane applications.
- Process and Material Control: Surfactants and delayed-action catalysts that control froth stability, cell structure and cure profile, from lay-down through post-cure.
- Tailored Innovation: From cushioning to thermal insulation, our additives adapt to your design and production needs.
Solutions by Application Area
Polyurethane Froth Foam for Battery Pads
Achieve superior foam stability, fine cell structure, and controlled curing for complex battery systems from EV packs to consumer electronics.
- TEGOSTAB® B 8984 – Highly potent froth surfactant providing superior froth stability and a fine, homogeneous cell structure in mechanically frothed foams at densities down to 200 kg/m³.
- TEGOSTAB® B 89120 – Next-generation low-VOC surfactant for lower densities down to 150 kg/m³, with excellent dimensional stability and homogeneous cell structure in mechanically frothed foams for demanding applications including electronics and lithium-ion batteries.
- TEGOSTAB® B 89177 and B 89178 – Surfactants for controlling cell size and distribution in medium- and high-density mechanically frothed foams. They can also be used as co-surfactants in low-density froth applications to improve froth stability and reduce cell coalescence during curing.
- POLYCAT® SA series – Heat-activated catalysts with customizable delayed reactivity for optimized processing and rapid post-curing under heat. No reaction occurs during frothing, delivery and lay-down; rapid cure follows once heat is applied.
- ORTEGOL® DA series – Non-ionic, NPE-free dispersing agents that reduce the viscosity of highly filled formulations, disperse aluminum trihydroxide and aluminum oxide fillers, and increase maximum filler loading. They do not interact with standard PU catalysts, so cure behavior is unaffected.
Your Evonik Advantage
- Reliable Performance: Additives engineered for stability, cushioning, and thermal resistance in EV battery environments.
- Process Efficiency: Delayed-action and temperature-activated catalysts that extend pot life without slowing cure.
- Expert Collaboration: Our technical teams work with you to optimize formulations and accelerate development.
Ready to Optimize Your Battery Pad Formulation?
Talk to our technical team about surfactant and catalyst selection for your froth foam density target and process.
Explore our solutions to start your journey toward high-performance material innovation.