Custom PP Bubble Board Solutions for EV Battery Pack Protection
As electric vehicles (EVs) continue to transform the future of mobility, ensuring the safety, performance, and efficiency of battery packs has become a top priority for automakers. One material that is gaining traction for its unique combination of strength, light weight, and versatility is PP Bubble Board. At Polyreflex, we offer custom PP Bubble Board solutions specifically designed to meet the rigorous demands of EV battery pack protection.
Why Do EV Battery Packs Need Specialized Protection?
The battery pack is the heart of an electric vehicle — and also its most sensitive and expensive component. Battery packs are subject to:
Using proper protection materials ensures not only structural integrity but also thermal safety and long-term durability. Traditional materials such as aluminum, solid plastics, and wood panels often come with downsides: they are heavy, costly, or difficult to recycle.
Advantages of Using PP Bubble Board for EV Battery Pack Protection
PP Bubble Board is a co-extruded polypropylene sheet with a bubble-structured core sandwiched between two flat layers. This unique design brings a wide range of benefits:
1. Lightweight yet Rigid
The bubble core dramatically reduces weight without compromising strength — a key factor in improving overall EV energy efficiency.
2. Excellent Impact Resistance
The air-filled bubbles act as shock absorbers, providing exceptional impact protection for the battery pack during vibration or collisions.
3. Thermal Insulation
The air gap within the bubble structure offers excellent insulation, helping regulate temperature around sensitive battery cells.
4. Waterproof and Chemical Resistant
PP is naturally resistant to moisture, oil, and most chemicals, ensuring reliable performance even in harsh environments.
5. Recyclable and Eco-Friendly
Made from 100% polypropylene, the board is completely recyclable and free of toxic substances such as heavy metals or halogens.
6. Flame Retardant Options
We offer flame-retardant PP Bubble Board grades to enhance safety in high-voltage battery systems.
7. Easy to Process
The board can be cut, welded, drilled, or thermoformed to fit the precise needs of different battery pack designs.
Custom Solutions by Polyreflex
With over 18 years of manufacturing experience, Polyreflex provides fully customized PP Bubble Board solutions tailored to your EV battery project:
Whether you need a rigid base plate, sidewall protection, or lightweight insulation layer, Polyreflex can deliver a solution engineered for performance and efficiency.
Real-World Application Example
A European EV manufacturer approached Polyreflex seeking a lightweight and fire-safe panel material for their battery pack underfloor protection. We recommended a 7mm flame-retardant PP Bubble Board, CNC-cut to fit their battery module frame.
The custom panels passed vibration and impact tests, as well as flame resistance evaluations required for high-voltage systems. By switching from traditional aluminum panels, the manufacturer reduced part weight by 38%, improving range and overall system performance.
PP Bubble Board vs Other Materials for Battery Pack Use
| Property | PP Bubble Board | Solid PP Sheet | Aluminum | Plywood / MDF |
| Weight | Very Light | Medium | Heavy | Heavy |
Strength-to-Weight | Excellent | Good | Excellent | Medium |
Flame Retardant Option | Yes (optional) | Limited | Yes | No |
Water & Chemical Resistance | Excellent | Excellent | Good | Poor |
| Recyclability | 100% Recyclable | Yes | Limited | Not recyclable |
| Cost | Cost-effective | Medium | High | Medium |
EV battery pack protection demands materials that are lightweight, durable, thermally efficient, and safe. PP Bubble Board checks all the boxes, making it one of the most practical and cost-effective choices for modern electric vehicle designs.
At Polyreflex, we specialize in delivering custom PP Bubble Board solutions that meet your performance, safety, and sustainability targets. Whether you're an EV manufacturer or a component supplier, we are ready to support your project from prototype to mass production.
Contact us today for a free consultation or sample. Let's build safer, lighter, and more efficient EVs together.
