H.B. Fuller EV Protect 4006

H.B. Fuller EV Protect 4006 is a liquid-applied, two-component, flame-retardant, low-density polyurethane foam material designed for the potting and encapsulation of battery cells in EV battery modules. EV Protect 4006 SFR offers battery design engineers the ability to increase the power density of their modules while enhancing safety and protection from thermal propagation. The ultra lightweight nature of the EV Protect 4006 SFR minimizes the weight impact to the battery modules. The semi-structural properties of the material also provide noise, vibration, and harshness benefits to the battery system by unitizing the battery module and absorbing external environmental impacts.

Product Type: 2K (2 component) Adhesive, Encapsulant

Application Area: Batteries, Electric Vehicle (EV)

Chemical Family: Polyurethanes (PU)

Features: Cost Effective, Excellent Substrate Adhesion, Fire Proof, Flame Retardant, Good Processability, Good Weather Stability, High Impact Resistance, High Insulation Properties, Light Weight, Low Density, Low Viscosity, Non Corrosive, Non-Outgassing, Room Temperature Curing, Self-Leveling, Vibration Resistance

Technical Data Sheet
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Enhanced TDS

Identification & Functionality

Chemical Family

Polyurethane Foam

Features & Benefits

Labeling Claims
Product Highlights

EV Protect 4006 SFR is generally dispensed using a high speed dynamic mixer head directly into the battery module. The low viscosity liquid is easily able to flow and self level at the bottom of the enclosure. Once leveled, the material will foam and rise to approximately 5 times volumetric expansion. After rising, the foam will crosslink and cure creating a semi-structural interconnected foam that encapsulates all components within the module. In the event of a thermal event, the foam will absorb, isolate, and insulate the cells to mitigate thermal propagation.

Typical Features & Benefits
  • No outgassing of Hydrogen gas during curing
  • Meets UL94 V0 Certification
  • Up to 5 Times Expansion Rate
  • Cost Effective - Low Volume Usage

Applications & Uses

Hand Mixing Instructions for Foams
  • Per the stated mix ratio, measure out (either by weight or volume) the appropriate portions of Part A and Part B as into a flat sided container.
  • The mixing container should be larger than the amount of total material being mixed to allow for vigorous mixing. For example, for 75 grams of total material we suggest a minimum size of 150 ml container for mixing. For larger amounts, adjust container size appropriately.
  • Generally it’s recommended to add the higher density part into the flat sided mixing container first and then add the other part gently on top of the first part. This helps limit pre-reaction of the materials to just the interphase. Scrape the side and bottom of the individual parts container’s to ensure nearly all the measured materials are added to the mixing container.
  • Start timer and immediately mix vigorously for 20-30 seconds with a spatula or flat sided stir stick. Thoroughly scraping the sides and bottom of cup while mixing. Mixed material should be homogeneous and uniform in appearance.
  • At end of mixing time, immediately pour mixed material into mold.
  • Immediately clean all tools used in preparations that you wish to reuse with solvent.


General Information

EV Protect 4006-A SFR / 4006-B SFR is a two-component material. Hand mixing may be difficult. It is recommended that an automated dispensing unit be used with dynamic mixer to mix material. Prior to use, stir the individual parts to ensure they are uniform and homogeneous. Mixing the 4006-A-SFR prior to use for 5 minutes is essential to achieve a consistent foam density and cell structure. Check the container bottom for sediment after mixing to ensure filler is mixed in. If an extended shutdown or break in produc tion has occurred (> 1 hour) re-mix part A side prior to use. Note: Pail or Drum size containers may require longer mixing times. Surface must be clean, dry, and free from grease, oil, wax and other surface contaminates.

Clean Up

For cleanup of EV Protect 4006 SFR, Methyl Ethyl Ketone, Acetone, Dibasic Ester, Ethyl Acetate, or Mineral Spirits are recommended. Confirm with equipment supplier for compatibility of recommended solvents in dispensing equipment. Mineral oil can be used to flush uncured materials from lines. To clean uncured material from tabletops, tools or spatulas, additional cleaning solvent options are Isopropanol and Denatured Alcohol.


Physical Form
Electrical Properties
ValueUnitsTest Method / Conditions
Dielectric Strength3.0kV/mmASTM D149
Dielectric Constant (at 1MHz)1.4-ASTM D-0150
Dissipation Factor (at 1MHz)0.029-ASTM D-0150
Volume Resistivity5.1 x 10¹¹ohm-cmASTM D-0257
Surface Resistivity7.7 x 10¹²ohmASTM D-0257
Cured Properties
ValueUnitsTest Method / Conditions
Foam Density (Free rise)0.16 - 0.19g/cm³-
Foam Density (Free rise)10 - 12pcf-
Hardness (at 24 hours)20 - 30-Shore A
Hardness (at 48 hours)35 - 45-Shore A
Operating Temperature Range-60 - 120°C
Thermal Conductivity0.05W/m-K-
Uncured Properties
ValueUnitsTest Method / Conditions
Viscosity (4006 BSFR, at 25°C)160cPs-
Viscosity (4006 ASFR, at 25°C)500cps-
Specific Gravity (4006 ASFR)1.17-D792/D1475
Specific Gravity (4006 BSFR)1.25-D792/D1475
Mix Ratio (by volume, 4006 BSFR)81--
Mix Ratio (by weight 4006 BSFR)86--
Mix Ratio (by volume, 4006 ASFR)100--
Mix Ratio (by weight 4006 ASFR)100--
Color (Blend)Light Amber--
Working Time (Blend, at 25°C)120sec-
Cream Time (at 25°C, Blend)180 - 240sec-
Tack Free Time (Blend, at 25°C)appprox. 60minutes-

Packaging & Availability

Regional Availability
  • Africa
  • Asia Pacific (Excluding Russia)
  • Europe (Excluding Russia)
  • India
  • Latin America
  • Middle East
  • North America
Typical Packaging
  • 5 gal Pails
  • 55 gal Drums
  • 300 gal Totes

Storage & Handling

Storage and Shelf Life

EV Protect 4006 SFR should be stored in a cool, dry place above 15°C (60°F). Purge open containers with dry nitrogen. Shelf life is a minimum of one year in unopened containers when stored at 25°C .