The Global EV Battery Polyurethane Foam Market was valued at USD 620 Million in 2025 and is projected to reach USD 1.28 Billion by 2034, growing at a Compound Annual Growth Rate (CAGR) of 8.5% during the forecast period (2024–2030). This remarkable growth is driven by the rapid global expansion of electric vehicle production, stringent safety regulations for battery packs, and the automotive industry’s relentless pursuit of lightweight, high-performance materials to extend driving range.

As the electric mobility revolution accelerates, the critical role of battery safety and thermal management has come to the forefront. Specialized polyurethane foams are essential for protecting sensitive battery cells from vibration, impact, and thermal runaway. In this blog, we profile the Top 10 Companies in the EV Battery Polyurethane Foam Industry—a dynamic mix of chemical giants, material science innovators, and component specialists shaping the future of safe and efficient electric transportation.

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🔟 1. Sekisui Chemical Co., Ltd.

Headquarters: Osaka, Japan
Key Offering: Flexible & Rigid PU Foams, High-Performance Sealing Materials

Sekisui Chemical is a global leader in polymer technology, providing advanced polyurethane foam solutions specifically engineered for EV battery modules. Their foams excel in vibration dampening, thermal insulation, and flame retardancy, meeting the most stringent automotive safety standards. The company works closely with major Asian battery manufacturers and automotive OEMs.

Innovation Initiatives:

• Development of ultra-lightweight foam formulations for enhanced energy density

• Advanced flame-retardant technologies to mitigate thermal runaway risks

• Strategic partnerships with leading EV manufacturers for customized solutions

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

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9️⃣ 2. Rogers Corporation

Headquarters: Chandler, Arizona, USA
Key Offering: BISCO® Silicone & Polyurethane Foams, PORON® Polyurethanes

Rogers Corporation is a premier materials science company renowned for its high-performance elastomeric solutions. Their BISCO and PORON product lines offer exceptional cushioning, sealing, and thermal management properties crucial for EV battery packs. Rogers’ materials are designed to withstand extreme temperatures and provide long-term reliability.

Innovation Initiatives:

• Proprietary foam formulations for compression set resistance and durability

• Solutions for battery cell stacking, gap filling, and impact absorption

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8️⃣ 3. BASF SE

Headquarters: Ludwigshafen, Germany
Key Offering: Elastoflex® Polyurethane Foam Systems, Elastocoat® Coatings

BASF, a global chemical giant, offers a comprehensive portfolio of polyurethane systems for the automotive industry. Their Elastoflex foams are tailored for battery applications, providing excellent adhesion, thermal stability, and flame retardancy. BASF’s strong R&D capabilities support the development of next-generation battery materials.

Innovation Initiatives:

• Bio-based polyol technologies for sustainable foam production

• Integrated solutions for battery pack assembly and thermal management

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7️⃣ 4. Henkel AG & Co. KGaA

Headquarters: Düsseldorf, Germany
Key Offering: Loctite® PU Foams, Bergquist Gap Pad® TIMs

Henkel is a leading global supplier of adhesives, sealants, and functional coatings. Their polyurethane foam products are critical for bonding, potting, and sealing battery modules. Henkel’s expertise in thermal interface materials ensures efficient heat dissipation from battery cells, enhancing safety and performance.

Innovation Initiatives:

• High-performance gap-filling foams for uneven surfaces

• Flame-retardant certified solutions for automotive battery standards

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6️⃣ 5. Saint-Gobain S.A.

Headquarters: Courbevoie, France
Key Offering: Specialty Polymer Foams, NORGLIDE® Bushings

Saint-Gobain provides engineered material solutions, including specialized polyurethane foams for vibration isolation and thermal insulation in EV batteries. Their materials are designed to endure harsh automotive environments and contribute to the structural integrity of battery packs.

Innovation Initiatives:

• Development of multi-functional foam composites

• Focus on materials that facilitate battery recyclability

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5️⃣ 6. Inoac Corporation

Headquarters: Tokyo, Japan
Key Offering: Custom-Molded PU Foams, Sound and Vibration Dampers

Inoac is a leading Japanese manufacturer of polymer products, specializing in custom-molded polyurethane foams for automotive applications. Their foams provide precise cushioning and insulation for various battery cell formats (prismatic, pouch, cylindrical), ensuring optimal performance and safety.

Innovation Initiatives:

• Precision molding for complex battery pack geometries

• Lightweight foam technologies to maximize vehicle range

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4️⃣ 7. Daicel Corporation

Headquarters: Osaka, Japan
Key Offering: Plastic Foams, Engineering Plastics

Daicel Corporation leverages its expertise in plastics and polymers to produce specialized foams for the EV sector. Their products focus on providing reliable thermal management and mechanical protection within battery packs, contributing to overall vehicle safety and longevity.

Innovation Initiatives:

• R&D in flame-retardant polymer additives

• Collaborations with battery makers for material testing and validation

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3️⃣ 8. Evonik Industries AG

Headquarters: Essen, Germany
Key Offering: ROHACELL® Foams, Specialty Polyols

Evonik is a global leader in specialty chemicals, offering high-performance materials for demanding applications. Their polyurethane foam solutions are engineered for excellent insulation properties and mechanical strength, playing a vital role in battery safety systems for electric vehicles.

Innovation Initiatives:

• Development of thermally conductive foam composites

• Sustainable material initiatives for the circular economy

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2️⃣ 9. 3M Company

Headquarters: Saint Paul, Minnesota, USA
Key Offering: 3M™ Polyurethane Foams, Adhesives & Tapes

3M brings its vast expertise in materials science to the EV battery market with a range of polyurethane foams and accompanying adhesive systems. These products are used for bonding, sealing, and cushioning battery components, ensuring reliability under vibration and thermal cycling.

Innovation Initiatives:

• Integration of foam solutions with adhesive technologies

• Focus on ease of application for automated manufacturing

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1️⃣ 10. H.B. Fuller Company

Headquarters: St. Paul, Minnesota, USA
Key Offering: Polyurethane Foam Adhesives, Encapsulants

H.B. Fuller specializes in formulating high-performance adhesives and sealants, including polyurethane-based systems for EV battery assembly. Their foams and adhesives provide strong bonds and seals that protect battery modules from moisture, dust, and mechanical stress.

Innovation Initiatives:

• Development of low-VOC and environmentally friendly formulations

• Solutions designed for high-speed automated battery production lines

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

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🔋 Outlook: The Future of EV Battery Safety is Smarter and More Integrated

The EV battery polyurethane foam market is undergoing a significant evolution. While basic cushioning remains important, the industry is increasingly demanding multi-functional materials that contribute to thermal management, structural integrity, and overall battery pack safety.

📈 Key Trends Shaping the Market:

• Development of thermally conductive foams for improved heat dissipation

• Increased adoption of flame-retardant (FR) formulations to meet strict safety standards like UL 94 V-0

• Integration of foam solutions with Battery Management Systems (BMS) for smart monitoring

• Growing focus on sustainable and recyclable foam materials aligned with circular economy principles

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

The companies listed above are not only supplying essential materials—they’re driving the innovation that makes electric vehicles safer, more reliable, and more efficient for a sustainable future.