Parker Hannifin expands CoolTherm line with new SF-1000 foam for battery safety

Parker Hannifin has introduced the CoolTherm SF-1000 Silicone Foam, a new liquid-dispensed thermal barrier aimed at enhancing safety in cylindrical lithium-ion battery packs. This innovative foam acts as a fire blanket within the battery assembly, designed to prevent thermal runaway propagation—a critical safety concern in electric vehicle and energy storage applications. The product is positioned as a solution that balances safety performance with improved manufacturability and design flexibility, responding to the growing demands of battery engineers. Traditional methods for managing battery thermal risks often involve potting materials, mica sheets, aerogels, or intracellular foams, many of which present challenges such as complex application processes or high labour intensity. CoolTherm SF-1000 distinguishes itself by being a non-expanding foam that can be precisely dispensed without the need for complicated mixing equipment. This ease of application supports continuous mass production and reduces assembly complexity, which is particularly valuable for manufacturers seeking to streamline their processes while maintaining stringent safety standards. Parker Hannifin highlights that the new foam can effectively replace rigid, die-cut mica sheets used in cylindrical cell packs, offering comparable safety benefits at a lower overall cost. Extensive testing, including evaluations by UL, has confirmed the material’s capacity to mitigate thermal runaway propagation effectively. Eric Dean, Business Development Manager at Parker Hannifin’s Assembly and Protection Solutions Division, emphasised that the product is designed to meet electrification needs across various markets, delivering enhanced safety alongside cost and complexity reductions. The launch of CoolTherm SF-1000 reflects broader industry trends where battery designers are under increasing pressure to develop safer, more efficient systems without escalating costs or manufacturing difficulties. As electric vehicle and energy storage technologies continue to advance, innovations like Parker’s new foam are likely to play a key role in improving battery pack safety while supporting scalable production. This development may encourage further adoption of liquid-applied thermal barriers and influence future design standards in battery safety.