IXPP Foam Protective Layer Cross-linked Closed Cell PP Foam Roll 1-6mm For New

IXPP Foam Protective Layer for New Energy Battery Packs

EKKOFLEX IXPP foam protective layer is an irradiation cross-linked closed cell polypropylene (PP) foam roll engineered for new energy battery applications, including EV/HEV battery packs, power battery modules and energy storage systems. Manufactured from polypropylene with a carefully controlled additive system through melt mixing, extrusion molding, green ion radiation cross-linking and continuous high-temperature foaming, the material forms an independent closed-cell structure with a closed-cell rate of over 98%.

Placed between battery cells, between modules, or between the module and pack enclosure, this IXPP foam roll acts as a multifunctional protective layer: it reduces heat transfer between cells, cushions cells against shock and vibration, provides electrical insulation, and keeps moisture and condensation away from the battery system, while adding only negligible weight to the pack.

Key Features

1. Thermal Insulation Between Cells - Low thermal conductivity (<0.036 W/m·K) reduces heat exchange between adjacent cells and modules, helping the pack maintain a more uniform temperature distribution in normal operating conditions.

2. Shock Absorption & Vibration Damping - The closed cell microcellular structure absorbs impact energy and dampens vibration during vehicle driving, handling and transport, protecting cells, busbars and weld joints from mechanical stress.

3. Moisture & Condensation Barrier - With a closed-cell rate over 98% and water absorption as low as ≤2%, the foam layer prevents humidity and condensation from reaching cells, connectors and the battery management system.

4. High Electrical Insulation - Cross-linked polypropylene is a non-conductive material with excellent electrical insulation properties, making the foam a reliable insulating spacer between cells and between the module and pack enclosure.

5. High Temperature Resistance & Dimensional Stability - Maximum continuous service temperature of 120°C with low thermal shrinkage keeps the protective layer dimensionally stable within battery operating temperature ranges.

6. Lightweight & High Strength - Density from 33.3 to 200 kg/m³ offers strong compressive support in thin protective pads while adding minimal weight, helping protect the energy density of the pack.

7. Customizable Processing - Supports die-cutting, slitting, adhesive backing and custom thickness, width and color to fit cell-to-cell pads, module liners and pack bottom protection sheets.

Product Photos

Product photos below show EKKOFLEX IXPP foam sheets, rolls and close-up views. Contact us for more application and customization photos.

Technical Specifications

General Specifications

IXPP Foam Technical Specification (by foam ratio)

Battery Protection Performance Comparison

Product Q&A

Q1: Why is IXPP foam used as a protective layer in new energy battery packs?
A: IXPP foam combines low thermal conductivity for cell-to-cell thermal insulation, closed cell cushioning for shock and vibration protection, excellent electrical insulation, and a moisture barrier in one lightweight material. It can be die-cut into thin pads that fit between cells or between the module and pack enclosure without adding significant weight.

Q2: Which thickness and density should be used for battery protection?
A: Typical protective layers use high density grades (5-15 times foam ratio, about 66-200 kg/m³) in 1-3mm thickness for firm support, or 3-6mm for higher cushioning. We can recommend the right grade and die-cut geometry according to your cell size, clearance and compression requirements.

Q3: Is IXPP foam electrically insulating?
A: Yes. Cross-linked polypropylene is a non-conductive material, and the closed cell structure gives IXPP foam excellent electrical insulation performance, making it suitable as an insulating spacer between cells and between the module and pack housing.

Q4: What temperature range can IXPP foam withstand?
A: IXPP foam has a maximum continuous service temperature of about 120°C with low thermal shrinkage and good dimensional stability, comfortably covering the normal operating temperature range of lithium battery packs.

Q5: Can the protective layer be customized?
A: Yes. We offer thickness from 1-6mm (single layer, up to 100mm multilayer), width from 500-1500mm, custom die-cut shapes, slitting, adhesive backing and color options to match your battery pack design drawings.

Q6: What certifications and order terms apply?
A: Products are manufactured under ISO 9001:2015 quality management and comply with RoHS and REACH requirements. MOQ is 500 square meters, with samples available on request. Contact us for technical data sheets and wholesale pricing.

Why Choose EKKOFLEX IXPP Battery Protection Foam

Sinopec-sourced polypropylene raw material, strict batch testing and years of irradiation cross-linking experience ensure every roll of EKKOFLEX IXPP foam delivers consistent density, uniform closed cell structure and dependable long-term resilience. We support new energy battery manufacturers, module assemblers and energy storage integrators with custom die-cut protective layers, fast sampling and stable mass supply. Contact us for pricing, samples and technical support.