APPLICATION SUCCESS STORY
The information contained in this Success Story is intended to assist you in designing with Rogers’ Elastomeric Material Solutions. It is not intended to and does not create any warranties,
express or implied, including any warranty of merchantability or fitness for a particular purpose or that the results shown in this Success Story will be achieved by a user for a particular
purpose. The user should determine the suitability of Rogers PORON products for each application. The Rogers logo and PORON are trademarks of Rogers Corporation or one of its
subsidiaries. © 2022 Rogers Corporation, All rights reserved. Printed in U.S.A. 1022-PDF. Publication #
17-475- www.rogerscorp.com
ROGERS HELPS PROVIDE A SAFE RIDE
Rogers’ PORON® 79 Material Delivers Multiple Benefits
Electrically-powered transportation has paved the way for electric bikes to increase in popularity across consumer markets. When choosing
the battery technology for an electric bike, a lithium-ion battery is ideal because it is lightweight and can store a relatively high amount of
energy.
CUSTOMER PROBLEM
The lightweight battery of an electric bike has multiple benefits to the rider such as helping the bike's rider go farther without a charge and
not adding additional weight to the bike as it travels. There are, however, potential issues battery designers must consider when it comes to
rider safety. To ensure a safe ride, the batteries must make use of a material that offers sufficient vibration protection as well as a protective
thermal barrier since the bike's battery will heat up while under operation. Additionally, this material solution must fit into the limited
amount of space available in the battery while not adding weight to the bike. One popular battery manufacturer contacted Rogers seeking
a material that could help them solve these safety design challenges.
THE ROGERS SOLUTION
The customer needed to solve two problems: shock absorption/cushioning and thermal resistance. The Rogers technical team
recommended PORON® 79 material, which has a unique open cell structure that is both breathable and durable, allowing the material to
absorb and distribute impact efficiently. PORON 79 polyurethane foam also displays great compression set resistance (the ability of a
material to resist collapse from the stresses of compression and temperature over time), which delivers long-term cushioning. The battery
manufacturer validated the vibration protection of the foam by subjecting the battery to a string of battery shaker tests. The testing proved
that the Rogers material successfully improved the overall safety of the battery by dampening structure-born vibration. PORON 79 foam also
has a UL-flammability rating (a standard test that verifies the material's flame resistance at certain temperatures) that helps create a thermal
barrier between the battery's pouch cells.
RESULT
With its UL-flammability rating and insulating capabilities, PORON 79 material mitigated thermal risk in the bike battery while
simultaneously absorbing shock and vibration to the battery pack. By using PORON 79 both as an interlayer between the cell packets within
the lithium-ion battery and as a bumper pad on either end of the battery, the battery manufacturer was able to solve two major issues with
a single material.
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