ProCell™ EV Firewall Barrier
ProCell™ EV Firewall Barrier is a specially formulated cellular silicone elastomer designed to delay thermal runaway and temperature spikes within electric vehicle battery packs, available in thicknesses from 0.059″ to 0.118″ with a density range of 24.97–44.76 lb/ft³ per ASTM D1056. It achieves a compression set of 3.0% at 22 hours @ 212°F @ 50% per ASTM D1056, a dielectric strength of 6.1 kV/mm, and a thermal conductivity of 0.15 W/m·K at both 122°F and 392°F per ASTM D5470. The material meets UL 94 V-0/5VA (certified for 0.118″ or thicker, tested at a 3rd party lab).
Key Properties
- Compression Force Deflection Range @ 25%: 7.25 – 18.13 psi (ASTM D1056)
- Tensile: 80.5 psi (ASTM D412)
- Elongation: 132% (ASTM D412)
- Compression Set, 22 Hours @ 212°F @ 50%: 3.0% (ASTM D1056)
- Density Range: 24.97 – 44.76 lb/ft³ (ASTM D1056)
- Thermal Conductivity @ 122°F / 392°F: 0.15 W/m·K / 0.15 W/m·K (ASTM D5470)
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- Specifications
- Applications
- General Info
- FAQs
Physical Properties
| Property | Value | Test Method |
| Thickness | 0.059″ – 0.118″ | — |
| Color | White | — |
| Density Range | 24.97 – 44.76 lb/ft³ | ASTM D1056 |
| Water Absorption @ 73.4°F | 1.2% | — |
Mechanical Properties
| Property | Value | Test Method |
| Compression Force Deflection Range @ 25% | 7.25 – 18.13 psi | ASTM D1056 |
| Tensile | 80.5 psi | ASTM D412 |
| Elongation | 132% | ASTM D412 |
| Tear Strength | 0.0015 kN/m | ASTM D624 |
| Compression Set, 22 Hours @ 212°F @ 50% | 3.0% | ASTM D1056 |
Thermal Properties
| Property | Value | Test Method |
| Thermal Conductivity @ 122°F | 0.15 W/m·K | ASTM D5470 |
| Thermal Conductivity @ 392°F | 0.15 W/m·K | ASTM D5470 |
| Specific Heat @ 73.4°F | 1.7 J/g·°F | — |
Electrical Properties
| Property | Value | Test Method |
| Dielectric Strength | 6.1 kV/mm | ASTM D419-97a |
Flame & Fire Performance
| Property | Value | Test Method |
| UL 94 | Meets V-0/5VA¹ | — |
¹ Testing only certified for 0.118″ or thicker and tested at a 3rd party lab.
Compliance
- UL 94 V-0/5VA — Compliant (certified for 0.118″ or thicker, tested at a 3rd party lab)
- Cell-to-cell thermal propagation barrier in electric vehicle battery packs to delay thermal runaway between adjacent cells
- Module-to-module firewall insulation in EV battery assemblies to contain temperature spikes during catastrophic thermal events
- Compressible dielectric barrier between battery cells requiring simultaneous electrical insulation (6.1 kV/mm) and thermal runaway suppression
- Flame-rated EV battery pack insulation requiring UL 94 V-0/5VA compliance at 0.118″ thickness
- Thermal management sealing components in EV battery enclosures requiring consistent thermal conductivity across a wide temperature range
Common industries: Electric vehicles, battery systems, automotive, energy storage.
ProCell™ EV Firewall Barrier is a specially formulated cellular silicone elastomer engineered specifically for cell-to-cell and module-to-module thermal propagation protection in electric vehicle battery packs. Its primary function is to delay thermal runaway and suppress temperature spikes during catastrophic thermal events, serving as a passive firewall barrier between adjacent battery cells or modules.
Available in thicknesses from 0.059″ to 0.118″ in white, the material is designed to deliver consistent performance across a wide temperature range, as demonstrated by a thermal conductivity of 0.15 W/m·K measured at both 122°F and 392°F per ASTM D5470 — confirming stable thermal behavior across the full EV battery operating envelope.
The material delivers a compression set of 3.0% at 22 hours @ 212°F @ 50% per ASTM D1056, a tensile strength of 80.5 psi, an elongation of 132%, and a tear strength of 0.0015 kN/m per ASTM D624. Compression Force Deflection at 25% ranges from 7.25 to 18.13 psi across the available density range of 24.97–44.76 lb/ft³. Dielectric strength is 6.1 kV/mm per ASTM D419-97a, specific heat at 73.4°F is 1.7 J/g·°F, and water absorption at 73.4°F is 1.2%.
Compliant with UL 94 V-0/5VA — testing certified for 0.118″ or thicker, tested at a 3rd party lab.
What differentiates ProCell™ EV Firewall Barrier from standard cellular silicone foams?
ProCell™ EV Firewall Barrier is specifically formulated for thermal runaway delay and temperature spike suppression in EV battery packs — a function not addressed by general-purpose cellular silicone foams. It demonstrates consistent thermal conductivity of 0.15 W/m·K at both 122°F and 392°F, confirming stable performance across the extreme temperature range experienced in a thermal runaway event. Its UL 94 V-0/5VA rating (certified at 0.118" or thicker at a 3rd party lab) adds the flame containment performance required in battery safety applications.
Why is compression set critical for this material?
In EV battery pack assemblies, the firewall barrier must maintain continuous, gap-free contact between adjacent cells or modules throughout the battery's service life and under sustained mechanical loading from cell expansion. A low compression set ensures the material recovers its original thickness after sustained compression, preserving the thermal and electrical insulation barrier interface. ProCell™ EV Firewall Barrier achieves 3.0% compression set at 22 hours @ 212°F @ 50% per ASTM D1056 — confirming excellent long-term recovery under the combined thermal and mechanical loads present in battery pack service.
What is the operating temperature range for ProCell™ EV Firewall Barrier?
No explicit operating temperature range is listed on the TDS. Thermal conductivity is reported at 122°F and 392°F per ASTM D5470, and compression set is tested at 212°F per ASTM D1056.
Is ProCell™ EV Firewall Barrier suitable for flame-rated environments?
Yes. ProCell™ EV Firewall Barrier meets UL 94 V-0/5VA. Testing is certified for 0.118" or thicker and was conducted at a 3rd party lab.
How should ProCell™ EV Firewall Barrier be specified?
Specify grade (ProCell™ EV Firewall Barrier), thickness (0.059" or 0.118"), target density or CFD range, UL 94 V-0/5VA compliance requirements (note: certified at 0.118" or thicker), dimensional tolerances, and finished format.
