Solution for Lightweight Application of Polyurethane Foam Adhesive in Two Wheel Electric Vehicles

Under the rapid development trend of new energy two wheeled electric vehicles, product design is iteratively upgrading towards lighter, safer, and more environmentally friendly directions. Especially in battery pack systems, traditional structural sealant is no longer able to meet the multiple requirements of the new national standard for vehicle quality, flame retardant rating, and cost control. Therefore, polyurethane foam (PUR Foam) has gradually become a key material for the manufacturing of two wheeled electric vehicles due to its advantages of lightweight, flame retardancy, and strong structural support.

Solution for Lightweight Application of Polyurethane Foam Adhesive in Two Wheel Electric Vehicles
This article by ELAPLUS will delve into the application of polyurethane foam adhesive in two typical scenarios: “foaming and sealing of battery packs for two wheeled electric vehicles” and “replacement of plastic structural frames”.
Application 1: Foam sealing of battery packs – balancing lightweight and safety performance
With the comprehensive upgrade of safety and energy efficiency standards for electric two wheelers by the country, weight control of battery systems has become an important part of vehicle compliance design. In the old scheme, traditional potting glue is usually used in quantities of over 2kg to ensure the fixation and protection of the battery cells. In the context of the new national standard, the weight must be compressed to within 400g, which puts higher requirements on the density and structural support performance of the sealing material.

Polyurethane foam adhesive solution
Recommended product: PUR 1685 A/B
Polyurethane foam adhesive
Mixing ratio: 1:1
Hardness: Shore D55, with rigidity close to that of plastic
Performance characteristics:
☑ After foaming, a sturdy structural layer is formed to support the battery module
☑ Reduce the overall number of parts and simplify assembly processes
☑ Excellent thermal insulation and heat resistance, enhancing safety redundancy
☑ Adjustable foaming ratio, suitable for different mold and structural requirements
This product foams evenly during the sealing process, which can completely fill the gaps inside the battery pack, firmly fix the battery cell module, and reduce the risk of structural damage caused by vibration or temperature changes. In addition, the cured material has good resilience and energy absorption properties, which helps to improve the overall impact resistance of the vehicle.
Application 2: Replacing Plastic Frameworks – A New Structural Approach to Reduce Costs and Increase Efficiency
In battery structure design, although traditional plastic frames have certain support functions, they have disadvantages such as high manufacturing costs, long injection molding cycles, and poor heat resistance. The use of high hardness polyurethane foam adhesive instead of plastic frames has gradually become a cost optimization direction in recent years.

Comparison of advantages of alternative solutions:
Project Plastic Frame PUR 1685 (2 #) Foam Adhesive
Cost is one fourth higher
Process injection molding+assembly mixed glue automatic sealing
Good structural support and stronger strength (hardness D55)
Environmental friendliness needs to consider recyclable and environmentally friendly formulas
Flame retardant grade requires additives to support default V-0 flame retardant
Faced with the rapid evolution of electric vehicle products, traditional material solutions are no longer able to meet the multiple challenges of safety, lightweighting, and cost control in the current industry. As a high-performance material, polyurethane foam adhesive not only brings breakthrough improvements to battery pack encapsulation, but also provides a feasible path for the replacement of structural components. Choosing PUR 1685 series foam adhesive will provide strong material support for the performance upgrade and market competitiveness enhancement of two wheeled electric vehicles.
If you need sample testing or technical support, please feel free to contact the ELAPLUS team. We will provide you with customized sealing and structural adhesive solutions.
Tags: Two wheel electric scooter sealing material · Foam rubber replaces plastic structure · Sealing material · Electric bike battery sealing support · Lightweight battery pack · Polyurethane foam rubber