Customer Background
A lithium battery module manufacturer in South Korea supplies battery packs for electric buses and passenger EV platforms.
They required a high-performance foam tape solution for:
Battery cell gap filling
Module vibration damping
Pack housing insulation support
Safety and durability were critical due to strict EV industry standards.
Challenge: Vibration Damage and Thermal Expansion Stress
The customer previously faced several production issues:
Foam compression failure after long-term vibration
Adhesive weakening near heat-generating battery zones
Poor cushioning between cells and aluminum housings
Increased risk of module loosening during transport
They needed a foam tape that could withstand:
Continuous vibration
Thermal expansion cycles
High safety compliance requirements
Solution Provided: Flame Retardant EVA Foam Tape
We supplied a flame retardant EVA foam tape designed for EV battery assembly applications.
Product Specifications
Foam type: FR-grade EVA foam
Thickness: 2mm
Adhesive: High-performance acrylic adhesive
Flame rating: UL94 V-0 available
Temperature resistance: –30°C to 120°C
Key function: cushioning + insulation + gap filling
Customization options included:
Die-cut foam pads for battery modules
High-density grades for structural support
Jumbo rolls for automated lamination lines
Results Achieved After 3-Month Validation
| Performance Metric | Improvement |
|---|---|
| Vibration-related module defects | ↓ 40% |
| Assembly stability | ↑ 25% |
| Foam compression durability | Improved significantly |
| Safety compliance acceptance | Passed internal OEM tests |
The foam tape provided consistent cushioning and reduced mechanical stress between battery cells and housings.
Why Foam Tape is Essential in EV Battery Packs
Foam tape plays a critical role in:
Shock absorption during driving vibration
Preventing cell movement and abrasion
Supporting thermal insulation layers
Improving pack safety and lifespan
Typical EV applications include:
Battery module spacing
Pack enclosure sealing
Sensor mounting protection
Cooling plate cushioning
FAQ
What foam tape is used for EV battery pack cushioning?
Flame retardant EVA foam tape with acrylic adhesive is commonly used to cushion battery modules and absorb vibration stress.
Can foam tape meet flame resistance requirements for lithium batteries?
Yes. We offer FR-grade foam tape options with UL94 V-0 ratings for EV and energy storage applications.
Do you provide die-cut foam tape parts for battery modules?
Yes. We supply custom die-cut foam pads and roll formats for automated EV battery assembly lines.