H.B. Fuller Polyurethane Foam 4006 is a two-component, flame-retardant, low-density polyurethane foam material. It is specifically designed for potting and encapsulation of battery cells within EV battery modules. This formulation enhances safety and protection against thermal propagation. It also significantly increases power density in modules.
General Information of H.B. Fuller Polyurethane Foam 4006
This H.B. Fuller Polyurethane Foam 4006 formulation utilizes a polyurethane foam base. It functions as an encapsulant. The product is a two-component system. It cures effectively at room temperature. Its appearance is a light amber, low viscosity liquid. This allows for easy flow and self-leveling within enclosures. The material then foams, expanding up to five times its original volume. Subsequently, the foam crosslinks and cures. This creates a semi-structural, interconnected foam. It effectively encapsulates all internal components. In a thermal event, the foam absorbs, isolates, and insulates cells. This mitigates thermal propagation efficiently.
Key Features & Technical Benefits
- Reduces Thermal Propagation: The foam actively absorbs and insulates, preventing heat spread.
- Ultra Lightweight: It minimizes weight impact on battery modules, optimizing overall vehicle mass.
- Low Viscosity & Self Leveling: This ensures easy dispensing and complete coverage of complex geometries.
- Great Vibration and Impact Resistance: It provides semi-structural support, absorbing external environmental impacts.
- Outstanding Insulation Properties: The material offers superior thermal and electrical isolation.
- No Outgassing of Hydrogen Gas: It ensures a safer curing process without hazardous gas release.
- Meets UL94 V0 Certification: This confirms high flame retardancy standards for critical applications.
- Up to 5 Times Expansion Rate: It provides efficient void filling with minimal material usage.
- Cost Effective – Low Volume Usage: High expansion reduces material consumption, lowering costs.
- Fast Processability: It allows for quick application and curing, streamlining production cycles.
Typical Industrial Applications
This formulation is engineered for the following applications:
- Potting of EV Battery Cells
- Encapsulation of EV Battery Modules
- Thermal Management in Electric Vehicle Systems
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| Property | Value |
| Color (Blend) | Lt. Amber |
| Working time at 25°C | 120 sec |
| Cream time at 25°C | 180-240 sec |
| Tack Free time at 25°C | ~ 60 min |
| Operating Temperature Range | -60 – 120 °C |
| Hardness at 24 / 48 hours | 20 – 30 / 35 – 45 Shore A |
| Foam Density – Free Rise | 0.16 – 0.19 g/cm³ (10 – 12 pcf) |
| Thermal Conductivity | 0.05 W/m-K |
| Dielectric Strength | 3.0 kV/mm |
| Dielectric Constant at 1MHz | 1.40 |
| Dissipation factor at 1MHz | 0.029 |
| Volume resistivity | 5.1 x 10¹¹ ohm-cm |
| Surface resistivity | 7.7 x 10¹² ohm |
