Battery End Plate Pads Built for Real-World BESS Demands

Designing battery energy storage systems (BESS) for 20+ years of performance isn’t just about capacity or efficiency—it’s about ensuring every component performs reliably under mechanical and environmental stress.

For engineers working on prismatic cell stacks, one of the most critical challenges is managing compressive force at the battery end plates. These pads must remain conformable, deliver consistent force deflection, and resist compression set over time, all while fitting precisely within tight, IP-rated enclosures.

Sur-Seal recently partnered with a BESS manufacturer to solve exactly that, helping turn demanding design requirements into a validated, production-ready solution.

The Challenge

This application required a material that could:

• Deliver equivalent compressive force deflection (CFD) at each battery end plate
• Resist compression set to ensure long-term mechanical stability
• Perform across a –20°C to +50°C operating range
• Conform to complex geometries and sealing surfaces
• Enable strong, reliable adhesion to mating surfaces
• Support IP55-rated protection against dust and moisture
• Be quickly prototyped, validated, and integrated into the design

The Solution

To meet the application’s demanding mechanical and environmental requirements, the team selected PORON® 4701-50 firm polyurethane foam from Rogers Corporation—a trusted material known for its consistent compressive force deflection (CFD), excellent compression set resistance, and reliable performance from –20°C to +50°C. Its durability and stability made it a strong fit for prismatic cell stack designs in battery energy storage systems (BESS).

As a Rogers Preferred Converter, Sur-Seal transformed this material into a production-ready solution—supporting engineers throughout the development process with:

• Fast-turn, laser-cut prototypes to accelerate design iterations
• Smart material layout and part nesting to support manufacturability and reduce waste
• Hands-on collaboration and technical support during design validation to ensure performance and fit across system components

By combining a proven Rogers material with Sur-Seal’s converting expertise, the project moved from concept to validated end plate pads on time and engineered for long-term reliability.

The Results

Prototypes in Days, Not Weeks

Sur-Seal delivered rapid-turn prototypes, enabling early testing of compressive force deflection (CFD) and part fit within the battery enclosure—keeping the development timeline on track.

Compression Set Resistance That Lasts

Parts converted from PORON® 4701-50 maintained their shape and performance under simulated operating conditions, giving engineers confidence in long-term system reliability.

Built to Scale

The solution has been integrated into current production platforms and is actively being evaluated for use in next-generation BESS designs, proving its repeatability at scale.

Ready to Solve Your Toughest Design Challenge? From rapid prototyping to production at scale, our experts are ready to help you engineer a reliable, long-lasting solution.

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