Battery & Energy Storage
Aviation battery packs combine closely spaced cells at meaningful voltage with continuous vibration exposure, which makes the materials holding the pack together do double duty: they need to bond and seal mechanically while also managing the electrical isolation between cells and enclosure. A material that only does one of those jobs well leaves the other as a failure point.
This page covers sealants and potting systems used to bond, seal, and encapsulate cells and modules in aviation battery packs.
Where This Is Used
Elastic sealants used to seal battery module and pack enclosures against moisture and contaminant ingress.
Structural bonding of cells to module bases and enclosure structures, absorbing vibration and CTE mismatch between components.
Potting and encapsulation systems filling the space between cells to provide mechanical support and thermal propagation protection.
Selection Factors
Reliable electrical isolation between cells and enclosure at the pack's actual operating voltage.
Moisture cure versus accelerated 2K cure, and how that fits the assembly line's takt time and process control.
Elasticity to absorb vibration and differential thermal expansion between cells, module base, and enclosure over the pack's service life.
Confirmed adhesion across the mix of composites, plastics, and metal typically found in a battery pack enclosure.
Whether the material needs to provide any barrier function in the event of a single cell thermal event, and to what degree.
Whether the pack design calls for a material that can be reworked for cell replacement, versus a permanent, non-serviceable joint.
Frequently Asked Questions
What's the difference between EV Seal 200 and EV Protect 300?
EV Seal 200 is an MS polymer sealant/adhesive primarily used for enclosure sealing and structural bonding at joints and seams. EV Protect 300 is a polyurethane potting system used to fully encapsulate cells within a module, which is a different job: it's filling space around components for mechanical support and propagation protection rather than sealing a joint between two surfaces.
Why would I choose a 1K moisture-cure sealant over a 2K accelerated system?
A 1K moisture-cure system simplifies the process by removing the need for metered mixing equipment, which can suit lower-volume or manual assembly. A 2K accelerated cure system trades that simplicity for a faster, more controlled cure schedule that's usually preferred on higher-volume automated lines where cycle time matters more than equipment simplicity.
Does potting a battery module make it impossible to service later?
Full encapsulation generally does reduce serviceability compared to a mechanically fastened or lightly bonded module, since removing cured potting material without damaging cells is difficult. This trade-off is usually made deliberately in exchange for the mechanical support and thermal propagation protection potting provides, so it should be a considered design decision rather than a default choice.
Are these products qualified for aviation battery applications specifically?
Both products are documented by the manufacturer primarily for electric vehicle battery applications. Qualification for a specific aviation battery program should be confirmed independently, since aviation certification requirements can differ from automotive EV requirements even where the underlying material technology is shared. Contact the technical team for documentation.
Do you provide support for battery pack material selection?
Yes. The Krayden technical team works directly with engineers on sealant and potting material selection, datasheets, and application support for new battery pack program qualification or production work.
Need Help Selecting a Battery Sealant or Potting System?
Selection depends on the cure process, dielectric requirements, and whether the design calls for serviceable or fully encapsulated cells. The Krayden technical team provides material selection support, datasheets, and application guidance across battery pack sealants and potting systems.
Battery & Energy Storage – Quick Reference
