The Global Battery Polyurethane Encapsulating Foam Market was valued at USD 188.3 Million in 2025 and is projected to reach USD 542.7 Million by 2034, growing at a Compound Annual Growth Rate (CAGR) of 12.5% during the forecast period (2026–2034). This robust growth is driven by the exponential rise in electric vehicle (EV) production, stringent battery safety regulations, and the critical need for advanced thermal management solutions to ensure battery pack integrity and longevity.

As the automotive industry undergoes a historic shift toward electrification, the materials ensuring the safety and performance of high-voltage battery systems are more important than ever. In this blog, we profile the Top 10 Companies in the Battery Polyurethane Encapsulating Foam Industry—specialty chemical manufacturers and material science innovators who are defining the standards for EV battery protection, thermal insulation, and structural support.

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🔟 1. Sekisui Chemical Co., Ltd.

Headquarters: Osaka, Japan
Key Offering: High-performance Polyurethane Foams for Battery Encapsulation

Sekisui Chemical is a leading global chemical company with a strong focus on high-performance polymers. Its expertise in polyurethane chemistry has positioned it as a key supplier of encapsulating foams that provide excellent thermal stability, flame retardancy, and vibration damping for lithium-ion battery modules in electric vehicles.

Key Innovations & Market Position:

• Development of low-density, high-resilience foams for lightweight battery packs

• Focus on flame-retardant formulations meeting stringent UL 94 V-0 standards

• Strategic partnerships with major Asian and European automotive OEMs

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9️⃣ 2. Inoac Corporation

Headquarters: Tokyo, Japan
Key Offering: Custom-engineered PU Foam Systems for EV Batteries

Inoac is a prominent manufacturer of polyurethane, plastic, and rubber products. The company specializes in developing custom foam solutions that encapsulate battery cells, providing critical protection against shock, vibration, and thermal runaway while ensuring efficient heat dissipation.

Key Innovations & Market Position:

• Proprietary foam systems with tailored compressibility and rebound characteristics

• Advanced manufacturing processes for high-volume automotive applications

• Strong presence in the Japanese and North American EV supply chains

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8️⃣ 3. Daicel Corporation

Headquarters: Osaka, Japan
Key Offering: Flame-Retardant Polyurethane Foams for Battery Packs

Daicel Corporation leverages its deep expertise in specialty chemicals and polymers to produce advanced polyurethane encapsulating foams. Its products are engineered to enhance the safety of EV battery systems by providing superior fire resistance and mechanical cushioning.

Key Innovations & Market Position:

• Innovation in halogen-free flame-retardant foam technologies

• Focus on improving thermal conductivity for better battery temperature management

• Expanding production capacity to meet growing global EV demand

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7️⃣ 4. Henkel AG & Co. KGaA

Headquarters: Düsseldorf, Germany
Key Offering: LOCTITE® Battery Encapsulation Solutions

Henkel is a global leader in adhesive technologies, and its LOCTITE® brand offers a comprehensive portfolio of polyurethane-based encapsulants and foams for the EV battery market. These materials are designed for automated dispensing and provide robust protection in challenging automotive environments.

Key Innovations & Market Position:

• Two-component PU foam systems with fast curing times for production efficiency

• Solutions that contribute to weight reduction and improved energy density

• Global technical support and collaboration with leading battery pack manufacturers

Download FREE Sample Report:
Battery Polyurethane Encapsulating Foam Market – View in Detailed Research Report

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6️⃣ 5. Saint-Gobain

Headquarters: Courbevoie, France
Key Offering: High-Temperature Resistant Encapsulation Foams

Saint-Gobain, through its specialist subsidiaries, provides advanced material solutions for extreme conditions. Its polyurethane foams for battery encapsulation are engineered to maintain structural integrity and insulating properties at the high operating temperatures typical within EV battery packs.

Key Innovations & Market Position:

• Development of foams with high thermal stability (withstanding temperatures exceeding 120°C)

• Expertise in combining thermal management with acoustic damping properties

• Strong R&D focus on next-generation battery technologies, including solid-state batteries

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5️⃣ 6. Prostech

Headquarters: Gyeonggi-do, South Korea
Key Offering: Custom PU Foam Solutions for Battery Module Assembly

Prostech is a specialized South Korean manufacturer focused on precision foam products for high-tech industries. The company provides critical encapsulating foam components that ensure precise spacing, compression, and insulation between cylindrical and prismatic battery cells.

Key Innovations & Market Position:

• Advanced die-cutting and fabrication capabilities for complex foam geometries

• Close collaboration with leading Korean battery giants like LG Energy Solution and SK On

• Focus on materials with low outgassing properties for sensitive battery environments

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4️⃣ 7. Rogers Corporation

Headquarters: Chandler, Arizona, USA
Key Offering: BISCO® Silicone and Polyurethane Foams for EV Batteries

Rogers Corporation is a renowned engineered materials leader. Its BISCO® brand offers a range of high-performance foams, including specialized polyurethane formulations used for sealing, cushioning, and thermal management within battery packs for electric and hybrid vehicles.

Key Innovations & Market Position:

• Portfolio includes both flexible and rigid PU foams to meet diverse design requirements

• Materials designed to resist degradation from coolants and other automotive fluids

• Strong technological heritage in materials science for demanding applications

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3️⃣ 8. Evonik Industries AG

Headquarters: Essen, Germany
Key Offering: Specialty Polyols and Additives for High-Performance PU Foams

Evonik is a global specialty chemicals company that plays a foundational role in the battery foam value chain. While not always a direct foam manufacturer, it supplies key raw materials—specialty polyols and additives—that enable foam producers to create products with enhanced fire resistance, thermal conductivity, and mechanical properties.

Key Innovations & Market Position:

• Development of sustainable polyols based on bio-based raw materials

• Innovative additive solutions for improving foam compressive strength and longevity

• Deep R&D in material science supporting the entire EV ecosystem

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2️⃣ 9. 3M Company

Headquarters: Saint Paul, Minnesota, USA
Key Offering: 3M™ Polyurethane Foam Tapes and Encapsulants

3M brings its vast expertise in adhesives and substrates to the EV battery market with a suite of polyurethane-based products. These include double-sided foam tapes for component bonding within the battery pack and flowable encapsulants that foam in place to provide cushioning and environmental sealing.

Key Innovations & Market Position:

• Acrylic and PU foam tapes that replace mechanical fasteners, reducing weight and complexity

• Materials certified to meet automotive OEM reliability and safety standards

• Global supply chain and technical service network supporting automotive manufacturers worldwide

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1️⃣ 10. HB Fuller Company

Headquarters: Saint Paul, Minnesota, USA
Key Offering: Engineering Adhesives and PU Foams for E-Mobility

HB Fuller is a leading global adhesives provider, offering formulated polyurethane systems for battery encapsulation. Its products are designed to be dispensed automatically into battery packs, where they expand to fill gaps, provide structural support, and protect cells from mechanical stress and environmental factors.

Key Innovations & Market Position:

• Focus on formulations with low volatile organic compound (VOC) emissions

• Development of thermally conductive variants to aid in passive thermal management

• Strategic focus on growing its market share in the rapidly expanding Asian EV sector

Get Full Report Here:
Battery Polyurethane Encapsulating Foam Market – View in Detailed Research Report

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🚗 Outlook: The Future of Battery Encapsulation Is Smarter and More Integrated

The battery polyurethane encapsulating foam market is evolving rapidly, moving beyond basic protection to become an integral, multi-functional component of the battery pack. The focus is shifting toward intelligent materials that contribute actively to battery safety, performance, and sustainability.

📈 Key Trends Shaping the Market:

• Development of thermally conductive foams that aid in heat dissipation, reducing the need for complex cooling systems.

• Rise of bio-based and recyclable polyurethane formulations to improve the environmental footprint of EV batteries.

• Integration of sensing capabilities within foam matrices to monitor pressure, temperature, and detect early signs of cell failure.

• Increased adoption of automated dispensing and foaming-in-place technologies to enhance manufacturing precision and speed.

The companies profiled above are not merely supplying a material; they are providing the essential safety backbone for the electric mobility revolution, enabling more reliable, efficient, and safer transportation for the future.

Get Full Report Here:
Battery Polyurethane Encapsulating Foam Market – View in Detailed Research Report