Features

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For a solution that is durable yet lightweight by nature, our Polyethylene Foam Sheets 2.2LB are the perfect solution. Made with the best in durability for longevity, and lightweight for ease of use without adding too much weight in packages, this foam solution offers a versatility that is unmatched.

There are a few reasons this foam type is a popular choice. For starters, it is an exceptionally strong material thanks to the fact it's closed cell polyethylene foam. This makes it tougher and longer lasting than open-celled foam solutions while making it a little stiffer. This foam is also resistant to rips, tears, stains, or grease which makes it ideal for a range of applications. It is also great for absorbing vibrations and impacts which makes it a popular choice for packaging of sensitive items or items that may be handled roughly during their long travel. Our Polyethylene Foam Sheets 2.2LB are a great solution for a range of applications thanks to the durable nature of the material.

Versatile Applications

In addition to packaging, Polyethylene Foam Sheets 2.2LB can be utilized in various other industries. For instance, they are excellent for cushioning in sports equipment, providing insulation in construction, and even in marine applications due to their water resistance. The versatility stems from their durable yet flexible nature, ensuring they meet diverse needs efficiently.

Custom Cutting is Available!
When you need a size or thickness not listed, we can cut custom sizes of polyethylene foam for any project. Please Contact Us for details.

Add Adhesive Backing for Easy Application!
If you are looking for an easy method to apply your foam to another surface, look no further than our adhesive backing. We can add this adhesive to a number of our closed-cell products. See Adhesive Backing for Foam for details!

Expanded Polypropylene (EPP)

Expanded Polypropylene (EPP) is a highly versatile closed-cell bead foam that provides a unique range of properties, including outstanding energy absorption, multiple impact resistance, thermal insulation, buoyancy, water and chemical resistance, exceptionally high strength to weight ratio and 100% recyclability. EPP can be made in a wide range of densities, from 15 to 200 grams per liter, which are transformed by molding into densities ranging from 18 to 260 grams per liter. Individual beads are fused into final product form by the steam-chest molding process resulting in a strong and lightweight shape.

How To Process EPP

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The manufacturing process is complex, requiring both technical expertise and specialized custom equipment. Polypropylene resin is combined with other ingredients in a multi-step proprietary process. Under tightly controlled conditions, extruded pellets expand to become consistently shaped beads of expanded polypropylene foam. Other specialized manufacturing techniques may be employed to produce variations in the final product form.

EPP foam beads are then injected into molds. In many cases, cost-effective multi-cavity aluminum molds are used. Pressure and steam heat fuse the beads into a finished shape. The finished EPP foam part becomes a key component in sub-assemblies incorporated in the original equipment manufacturer’s product.

Properties

Grades Available

EPP is available in grades necessary for a wide range of applications, based on the technical requirements. High density grades are used where energy management is important, such as automotive bumpers and interior passenger safety components. Low density grades are used for packaging applications, and medium densities find applications in furniture and other consumer products.

Low Emission grades minimize outgassing of VOCs for automotive interior parts. Anti-static, dissipative and conductive grades, typically used for special packaging requirements, are available.

Unique performance characteristics

Porous EPP is comprised of cylinder-shaped polypropylene beads, which adds air space between the beads in the final molded form, which enhances beneficial acoustical insulating effects and reduces weight.

EPP is commonly colored black for automotive applications, though is often found in white for packaging products. EPP is available from some suppliers in vibrant colors suitable for presentation-grade textured surface.

Physical Properties

EPP density range, from 20 g/l through 200 g/l

Tensile strength (kPa) 270 to 1930
Tensile elongation (%) 21 to 7.5

Compressive strength (kPa)
25% strain 80 to 2000
50% strain 150 to 3000
75% strain 350 to 9300

Compression set (%)
25% strain, 22H, 23°C 13.5 to 10.5
Burning rate (mm / min) 100 to 12

Resistance to Chemicals

Applications

EPP is widely utilized by automotive manufacturers because of its performance benefits for energy management, lightweight, enhanced functionality, durability and recyclability. Applications include seating, bumpers, stowage systems, door panels, pillars, floor levelers, parcel shelves, head rests, tool kits, sun visors and myriad filler parts.

Reusable industrial packaging, known as dunnage, is frequently made from EPP due to its durability and its inherent ability to absorb energy in transit. EPP is used increasingly in furniture, toys such as model aircraft and other consumer products due to its versatility as a structural material and its light weight, as well as other beneficial performance characteristics.

EPP is approved for use in conjunction with food products. Its thermal insulation properties and structural strength make it appropriate for containers such as food delivery containers and beverage coolers and the like. EPP does not support microbial growth and can be made sterile with steam cleaning.

History of EPP

EPP was first developed in the 1970's as a result of research into new forms of polypropylene. The material's first applications were for automotive products in Japan in 1982. Demand for EPP has since increased dramatically in all regions of the world based partly on the need of auto makers to improve energy management functions whilst reducing weight and improving environmental benefits. The first automotive application for EPP was for an energy absorbing component in a bumper system. EPP is now widely utilized for numerous other automotive parts and systems, including seating and other interior components.
 

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