HVAC insulation foam is a closed-cell polyethylene foam used to wrap chilled-water pipes, refrigerant lines, air-conditioning ducts and unit panels. Because every cell is sealed, the foam resists condensation, does not absorb water and holds a stable thermal conductivity over the working life of the system.
Bofeng Foam manufactures XPE, IXPE and IXPP foam in Zhuhai, China and supplies it to HVAC equipment makers and insulation contractors as plain sheet, self-adhesive roll, foil-faced laminate and die-cut panels.
What is HVAC Insulation Foam?
HVAC insulation foam is a flexible, closed-cell foam that combines thermal insulation with condensation control, acoustic damping and a degree of mechanical protection. It is wrapped around pipes and ducts, bonded to air-conditioner panels and used as the insulating layer inside duct sections and equipment casings.
- Condensation control — a sealed cell structure stops moisture vapour from entering the insulation, which is what causes dripping and corrosion on chilled lines.
- Thermal insulation — low thermal conductivity slows heat gain or loss, reducing compressor load and energy use.
- Acoustic damping — the foam absorbs airborne noise and damps panel vibration from fans and compressors.
- Chemical and moisture resistance — the foam does not rot, and does not support mould growth the way open-cell materials can.
Foam Materials for HVAC Insulation
XPE Foam
Chemically cross-linked polyethylene foam. Expansion ratio 3–40x, apparent density 26.8–300 kg/m³, single-layer thickness 3–15 mm and laminated builds from 15 to 200 mm, in widths of 500–2000 mm. Thermal conductivity runs from 0.040 to 0.095 W/m·K depending on density, and water absorption stays at or below 0.4%.
IXPE Foam
Irradiation cross-linked polyethylene foam, produced without a chemical cross-linking agent. Single layers start at 0.1 mm, which suits thin duct liners and panel backing where space is tight. It resists water, seawater, oils, acids and alkalis, and flame-retardant and low-smoke grades are available with a limiting oxygen index of 27.
IXPP Foam
Irradiation cross-linked polypropylene foam, the most heat-resistant grade in the range. Expansion ratio 5–25x, single-layer thickness 1–6 mm, laminated builds 6–100 mm, widths 500–1500 mm, and a maximum service temperature of 140 °C with resistance to boiling water. This is the grade for hot lines and equipment surfaces where polyethylene foam would soften.
Foil-Faced and Self-Adhesive Laminates
Foam can be laminated with aluminium foil to add a reflective surface and a vapour barrier, and coated with a solvent-based adhesive protected by a release liner so the installer can wrap pipes without separate glue. Multi-layer thermal bonding is available up to 100 mm thick.
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HVAC Insulation Foam Specifications
| Property | XPE | IXPE | IXPP |
|---|---|---|---|
| Cross-linking | Chemical | Irradiation (electron beam) | Irradiation (electron beam) |
| Expansion ratio | 3–40x | 3–40x | 5–25x |
| Single-layer thickness | 3–15 mm | 0.1–15 mm | 1–6 mm |
| Laminated build | 15–200 mm | 15–200 mm | 6–100 mm |
| Sheet width | 500–2000 mm | 500–2000 mm | 500–1500 mm |
| Thermal conductivity | 0.040–0.095 W/m·K | 0.040–0.095 W/m·K | Lower than PE foam |
| Water absorption (GB/T 1034) | ≤0.4% | ≤0.4% | — |
| Compression set, 23±2 °C / 22 h (GB/T 6669) | ≤10% | — | — |
| Maximum service temperature | — | — | 140 °C |
An optional flame-retardant grade is available across the range with a limiting oxygen index of 27, meeting GB 8410 A0 and UL94 V2. Multi-layer thermal bonding is available up to 100 mm, and foam can be supplied with aluminium foil facing and a solvent-based adhesive under a release liner.
HVAC Insulation Foam Products We Make
These application pages cover the HVAC products Bofeng Foam manufactures every day:
- Air conditioner pipe insulation foam
- Central air-conditioning duct insulation foam
- Tee pipe insulation foam
- Pipe insulation foam
- Air conditioner panel foam
How to Choose Foam for Ducts, Pipes and Panels
- Line temperature. Chilled water and refrigerant lines take XPE or IXPE. Hot lines and equipment surfaces that exceed the working range of polyethylene take IXPP, which is rated to 140 °C.
- Condensation risk. The higher the ambient humidity and the lower the line temperature, the more the specification depends on a fully closed cell structure and a sealed, foil-faced surface.
- Thickness. Required thickness follows the line temperature, the ambient conditions and the condensation-control standard the installer works to. We supply XPE from 3 mm and IXPP from 1 mm in single layers, and can laminate to thicker builds.
- Fixing method. Self-adhesive backing speeds up pipe wrapping; plain sheet suits duct liners and panel bonding where the foam is fixed with a separate adhesive or mechanically.
- Fire performance. Where a project specifies flame-retardant foam, the high flame-retardant grade has a limiting oxygen index of 27 and meets GB 8410 A0 and UL94 V2.
Why Choose Bofeng Foam as Your HVAC Foam Manufacturer?
Bofeng Foam is a direct manufacturer of cross-linked polyolefin foam, operating five production lines with an annual capacity of 5,000 tonnes from 10,000 m² of workshops in Zhuhai, China. Because the foam is made in-house, lamination, adhesive coating and die-cutting are handled end to end by one supplier rather than being subcontracted.
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HVAC Insulation Foam FAQ
What foam is used for air-conditioner pipe insulation?
Closed-cell polyethylene foam — usually XPE or IXPE. The sealed cell structure is what prevents condensation from being absorbed into the insulation, and the foam can be supplied self-adhesive and foil-faced so a contractor can wrap a line in one pass.
Is XPE foam suitable for hot pipes?
XPE and IXPE are specified for chilled and ambient-temperature lines. For hot lines and surfaces above the working range of polyethylene, IXPP is the correct grade: it is rated to a maximum service temperature of 140 °C and resists boiling water.
Can the foam be supplied with adhesive and a foil facing?
Yes. Foam can be coated with a solvent-based adhesive under a release liner, and laminated with aluminium foil. Multi-layer thermal bonding is available up to 100 mm thick, and the foam can also be embossed or printed.
Related Reading
See also: Pipe insulation foam: material, thickness and foil facing · All cross-linked foam materials · Flooring & construction foam · Contact Bofeng Foam