Posted 12 Sep 2025 16:23 | 24 views

Discover non-cellular elastomers for EV battery packs—safer than foams with superior vibration resistance, thermal runaway protection, and long-term reliability.

Non-cellular Elastomers: A Safer Alternative for Next-generation EV Battery Packs

As the e-mobility industry continues to grow rapidly, the safety and durability of battery packs have become a top priority for manufacturers. One of the biggest challenges lies in selecting protective and sealing materials for battery packs. Traditionally, foams have been widely used—but they come with limitations such as unpredictable expansion, void formation, and inconsistent performance.

To overcome these challenges, non-cellular elastomers have emerged as a safer, more reliable, and more consistent solution for next-generation battery packs.

Why Choose Non-cellular Elastomers?

Unlike foams that may expand unevenly and leave gaps, non-cellular elastomers cure into a dense, uniform structure. This ensures consistent quality, reliable structural integrity, and long-term performance throughout the battery’s lifespan.

Key Advantages of Non-cellular Elastomers

Thermal runaway mitigation – contain and isolate flames, reducing propagation risk
Vibration and impact resistance – protects cells from mechanical stress and chafing
Moisture and chemical resistance – resist corrosion in harsh environments
Manufacturing consistency – predictable, consistent material every time

Proven Solutions for EV Battery Safety

Today, several non-cellular elastomer formulations have already been validated and adopted in the automotive industry. Each solution is designed to meet specific requirements of battery pack design, ensuring enhanced safety, reliability, and consistency.

Below are a few of our proven non-cellular elastomer solutions


S7634: High-Performance Potting Uses: BMSs, DC/DC converters, GPS sensors 2-component polyurethane UL 94 V-0 flammability rating Free of halogens and tri-phenyl phosphate-type flame retardants Use across a temp range -40°C-130°C		S7633: UL 94 V-0 Potting Compound Uses: battery packs, other electrical applications 2-component polyurethane UL 94 V-0 flammability rating at 9mm Designed for an RTI rating >140°C Great combination of a low CTE and low Tg


S7634: High-Performance Potting Uses: BMSs, DC/DC converters, GPS sensors 2-component polyurethane UL 94 V-0 flammability rating Free of halogens and tri-phenyl phosphate-type flame retardants Use across a temp range -40°C-130°C		S7633: UL 94 V-0 Potting Compound Uses: battery packs, other electrical applications 2-component polyurethane UL 94 V-0 flammability rating at 9mm Designed for an RTI rating >140°C Great combination of a low CTE and low Tg

Reach out to our experts to explore the right non-cellular elastomer solution for your battery design.
⇒ sales@mostori.com
⇒ 033-641800
⇒ www.mostori.com