Safe Battery Potting for E-Mobility with ViscoTec & Von Roll
As the e-mobility revolution accelerates, safe and sustainable battery technology has become a critical focus area. Whether for electric vehicles, e-bikes, or two-wheelers, reliable energy storage requires clean, precise production methods—especially when it comes to potting battery modules.
The engineering team at Von Roll set out to test whether a lab-scale battery potting process could scale up for full production—using two-component polyurethane resin and the ViscoDuo-VM 12/8 dispenser.
Test Setup at ViscoTec’s Technical Center
Von Roll selected Dolph’s Damival 13682 and 13683, two-component polyurethane resins, for their test battery module—a dummy aluminum tray with cylindrical cells. The goal: evaluate if their materials, when dispensed with high accuracy and no air bubbles, could ensure:
Electrical insulation
Mechanical stability
Thermal conductivity
Fire resistance
Why ViscoTec’s ViscoDuo-VM Was Chosen
The ViscoDuo-VM 12/8 is a valveless 2K dispensing system that uses progressive cavity pump technology. Key benefits for battery potting:
✅ Precise, repeatable volumetric dosing
✅ No valves = fewer wear parts
✅ Excellent for filled or sensitive resins
✅ Bubble-free filling even with heated components
✅ Reliable stop/start with zero material waste
Von Roll praised its homogeneous surface quality and ability to maintain resin properties across different formulations—ideal for their diverse product applications.
Bubble-Free Potting = Fire-Safe Batteries
Why is air-free potting essential?
Even tiny air pockets can act as ignition accelerants in impact scenarios. Through careful resin heating and precise mixing ratios, Von Roll ensured perfect curing and consistent results.
The result? A battery potting process that's scalable, safe, and ready for mass production.
Want to learn more about potting safety? See this primer on Battery Fire Risks & Thermal Runaway
Future-Proofing Production with Modular Technology
The modular design of ViscoTec’s systems gives manufacturers like Von Roll the confidence to:
Transition smoothly from lab to production
Maintain long service intervals
Replace parts easily at module level
Handle multiple 2K material types with one system
For companies in EV battery manufacturing, electronics, or high-performance insulation, this flexibility is a game-changer.
Get ViscoTec Systems in the UK via Capri Systec
Capri Systec is the exclusive UK distributor of ViscoTec, offering expert guidance and integration support for complex dispensing challenges.
Whether you're working with potting compounds, adhesives, or pastes, our team helps you design a cost-effective, scalable, and future-ready solution.
Ready to improve battery safety and consistency?
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