Optimize EV Battery Performance with PORON® EVExtend® Foam Pads

Why Battery Pads Matter in EV design 

A vehicle’s operating environment is full of forces that can wreak havoc on a battery system — particularly mechanical stress, shocks and vibrations.

While electric vehicles (EVs) do provide a much smoother ride compared to traditional gas engines, the battery pack — whether made of pouch, prismatic or solid state batteries  — still requires adequate cushioning and shock absorption for safe and reliable operation. All the while, these high energy batteries require consistent pressure. 

Enter the battery pad. PORON EVExtend® Battery Pad Material provides the required level of firmness required in higher-energy batteries used in EV and hybrid vehicles, offering long-term performance and functionality in your EV battery design. 

In this blog, we’ll outline what it does and how it will enhance battery performance and safety, and how SRP can customize it for your needs. 

What is PORON EVExtend Battery Pad Material?

PORON EVExtend Battery Pad Material is a high-performance option that’s designed to endure the stresses that are unique to the EV operating environment. 

EV battery cells expand and contract to a great degree during charging and discharging cycles. To address this, PORON EVExtend® provides the right balance of compression set resistance and stress relaxation. It’s compressible material that offers that just-right, Goldilocks level performance by: 

  • Flexing with the cycles of expansion and contraction
  • Maintaining adequate pressure to hold batteries securely in place. 

But its main advantage comes from its durability. PORON EVExtend is engineered for long-term durability, retaining its cushioning and protective properties throughout the battery’s lifecycle. 

Key Benefits of PORON EVExtend 

  • Constant pushback force: Maintains steady pressure to hold cell batteries in place. 
  • Dynamic response: Adapts to fluctuations during charging and discharging cycling. 
  • Extended life: Retains compression and maintains original thickness for the life of the battery.  
  • Temperature resilience: Operates under a wide range of temperatures, from -20 degrees Celsius to 121 C.  (Recommend constant use 90 C.) 

Custom PORON EVExtend for your design 

As a longtime Preferred Converter of Rogers Corporation, SRP offers unmatched expertise in converting PORON EVExtend into precise components for your EV battery pack. 

  • Direct sourcing: We procure EVExtend directly from the manufacturer. Count on high quality, expedited shipping and competitive pricing. 
  • Custom die-cutting: Our decades of advanced die-cutting experience mean we can shape PORON EVExtend to fit your EV battery back with precision, even at high volumes. 

Learn more about our precision die-cutting services. 

Learn more about EV materials in our latest Ebook, The Future is Electric: An OEM’s Guide to Sourcing Die-Cut Battery Components for EV Production. 

Start Your Project with a Trusted Rogers Converter

Ready to get started on your EV project? Contact the team at SRP, and we’ll prepare a fast and accurate quote.