Top 10 Companies in the Battery Polyurethane Encapsulating Foam Market (2026): Market Leaders Powering Global Energy Storage

MARKET INSIGHTS

The global Battery Polyurethane Encapsulating Foam market was valued at USD 1.28 billion in 2025. It will rise from USD 1.42 billion in 2026 to USD 2.98 billion by 2034, reflecting a Compound Annual Growth Rate of 9.7 % during the forecast period.

Battery Polyurethane Encapsulating Foam is a thermoset polymer engineered to provide thermal insulation, mechanical cushioning, and protection against moisture and vibration within battery packs. By surrounding individual cells, it forms a barrier that mitigates thermal runaway and reinforces structural integrity, making it indispensable for modern electric vehicles.

The market’s expansion is largely driven by the exponential growth of electric vehicles. Government mandates for emission reductions and rising consumer adoption of EVs amplify demand, while challenges such as stringent fire safety standards and raw material price volatility temper growth. The Flexible Polyurethane Foam segment is poised to lead, thanks to its superior energy absorption, and leading players are actively developing advanced fire‑retardant formulations to capture this opportunity.

Battery Polyurethane Encapsulating Foam Market – View in Detailed Research Report

1. Sekisui Chemical (Japan)

   Headquarters: Tokyo, Japan
   Key Offering: Flexible polyurethane foams for battery encapsulation

   Sekisui has a long‑standing reputation for high‑performance foams and has recently introduced a low‑density, flame‑retardant formulation tailored to large‑format battery packs. The company’s R&D focus on bio‑based polyols aligns with the sustainability priorities of OEMs.

   Sustainability & Growth Initiatives:

   • Investment in renewable polyol sourcing
   • Partnerships with battery gigafactories in China and South Korea
   • Targeted development of 2K foam systems for prismatic cells

2. Henkel (Germany)

   Headquarters: Düsseldorf, Germany
   Key Offering: Advanced encapsulating foams with integrated flame retardancy

   Henkel’s expertise in specialty polymers has positioned it as a preferred supplier for OEMs seeking lightweight, high‑performance solutions. Recent product launches focus on reducing density while maintaining thermal stability.

   Sustainability & Growth Initiatives:

   • Commitment to carbon neutrality across manufacturing lines
   • Collaboration with automotive partners on joint R&D for solid‑state battery foams
   • Expansion of regional production facilities in North America

3. Rogers Corporation (USA)

   Headquarters: Pittsburgh, Pennsylvania, USA
   Key Offering: High‑temperature resistant foams for fast‑charging battery modules

   Rogers leverages its advanced material science capabilities to deliver foams that withstand the thermal cycling of fast‑charging EVs, a critical requirement for high‑capacity packs.

   Sustainability & Growth Initiatives:

   • Development of non‑halogenated flame retardants
   • Strategic alliances with EV OEMs for end‑to‑end thermal management solutions
   • Investment in automated dispensing technology

4. Evonik Industries (Germany)

   Headquarters: Essen, Germany
   Key Offering: Flame‑retardant polyurethane foams with enhanced mechanical protection

   Evonik’s portfolio includes foams engineered for both high‑temperature stability and low density, addressing the dual demand for safety and weight reduction in EV batteries.

   Sustainability & Growth Initiatives:

   • Use of bio‑based additives to lower carbon footprint
   • Participation in EU circular economy initiatives
   • Expansion of production capacity in the EU

5. 3M (USA)

   Headquarters: Saint Paul, Minnesota, USA
   Key Offering: Customized foams for battery pack integration

   3M’s strong technical support network enables rapid prototyping and testing, helping OEMs meet evolving safety standards.

   Sustainability & Growth Initiatives:

   • Development of recyclable foam chemistries
   • Collaboration with battery manufacturers on end‑of‑life solutions
   • Investment in process optimization to reduce energy consumption

6. Saint‑Gobain (France)

   Headquarters: Paris, France
   Key Offering: High‑performance insulating foams for battery modules

   Saint‑Gobain’s materials combine excellent thermal insulation with flame‑retardant properties, making them suitable for high‑voltage battery packs.

   Sustainability & Growth Initiatives:

   • Integration of renewable raw materials
   • Partnerships with European OEMs on low‑emission production
   • Research into biodegradable foam additives

7. Prostech (South Korea)

   Headquarters: Seoul, South Korea
   Key Offering: Two‑component foams for prismatic and pouch cells

   Prostech’s 2K systems offer precise control over cure time and density, which is critical for meeting the tight tolerances of modern battery designs.

   Sustainability & Growth Initiatives:

   • Development of low‑VOC formulations
   • Collaboration with Korean battery giants for joint product development
   • Expansion of regional supply chain capabilities

8. Inoac (Japan)

   Headquarters: Tokyo, Japan
   Key Offering: Flexible foams with advanced flame‑retardant additives

   Inoac focuses on delivering foams that meet the stringent fire safety requirements of EV manufacturers while maintaining low weight.

   Sustainability & Growth Initiatives:

   • Investment in renewable polyol research
   • Partnerships with OEMs for lifecycle assessment
   • Development of high‑performance foams for electric scooters and bikes

9. Daicel Corporation (Japan)

   Headquarters: Tokyo, Japan
   Key Offering: High‑temperature resistant foams for battery packs

   Daicel’s foams are engineered to withstand the thermal cycling of fast‑charging EVs, supporting the industry’s move toward higher energy densities.

   Sustainability & Growth Initiatives:

   • Use of bio‑based additives
   • Collaboration with battery pack manufacturers on integrated solutions
   • Investment in advanced curing technologies

10. HB Fuller (USA)

    Headquarters: Springfield, Missouri, USA
    Key Offering: Specialty foams for battery encapsulation and protection

    HB Fuller offers a range of foams that combine mechanical cushioning with flame retardancy, catering to OEMs seeking a single solution for multiple safety requirements.

    Sustainability & Growth Initiatives:

    • Development of recyclable foam systems
    • Partnerships with EV manufacturers on sustainability metrics
    • Expansion of production capacity in the United States

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Outlook

The Battery Polyurethane Encapsulating Foam market is set for continued expansion as the electric vehicle sector deepens its focus on safety and performance. The increasing shift toward high‑capacity, fast‑charging battery packs will demand foams that combine lightweight properties with robust thermal management. Manufacturers that invest in bio‑based formulations and advanced flame‑retardant technologies will be better positioned to capture the growing share of OEMs prioritizing sustainability and regulatory compliance.

Key Future Trends Shaping the Market

• Rapid adoption of flexible polyurethane foams driven by the need for vibration isolation in larger battery modules.
• Emergence of bio‑based polyols reducing the carbon footprint of foam production.
• Growth of integrated thermal management solutions that pair foam encapsulation with active cooling systems.
• Increased demand for recyclable foam chemistries aligned with circular economy initiatives.
• Expansion of regional manufacturing hubs in Asia‑Pacific to support just‑in‑time supply chains for EV production.