Parker Hannifin has introduced a new silicone foam material aimed at improving battery safety in cylindrical lithium-ion cell packs. The product, CoolTherm SF-1000, is a liquid-dispensed, non-expanding thermal barrier designed to mitigate thermal runaway propagation while simplifying manufacturing processes.

The material is positioned as an alternative to conventional thermal barrier approaches such as die-cut mica sheets, aerogels, potting compounds, and expanding foams. These incumbent solutions can introduce challenges in high-volume production, including complex mixing requirements, limited placement control, and added assembly steps.

CoolTherm SF-1000 is dispensed as a liquid and does not expand during curing, allowing for more precise placement within the battery pack. This enables targeted protection between cells while reducing the risk of material overflow or interference with adjacent components.

According to Parker, the foam acts as a localized fire barrier within cylindrical cell arrays, helping to slow or prevent propagation during thermal runaway events. The company states that internal and UL testing support its effectiveness in this role, although detailed performance data has not been disclosed.

A key focus of the material is reducing system-level cost and complexity. By replacing rigid, pre-formed barriers such as mica sheets, the foam can eliminate cutting, handling, and placement steps, while also offering greater flexibility in pack design.

The launch reflects a broader trend in battery pack engineering toward materials that integrate safety, manufacturability, and cost efficiency. As cell formats and pack architectures continue to evolve, demand is increasing for solutions that can be applied in-line and scaled for mass production without compromising safety performance.

CoolTherm SF-1000 expands Parker’s existing portfolio of thermal management and battery protection materials, targeting applications across electric vehicles and other electrified systems using cylindrical lithium-ion cells.

 Click here to read the latest issue of E-Mobility Engineering.