Name: XPS Foam Core for Composite Sandwich Panels
Brand: RaxPanel
Availability: MadeToOrder

XPS Foam Core

Extruded Polystyrene (XPS) Foam Core features a closed-cell structure formed through a continuous extrusion process, giving the board uniform cellular composition and stable dimensions across wide temperature ranges. The closed-cell construction blocks water intrusion, so the core keeps performing in humid conditions while delivering dependable compressive strength and thermal resistance for energy-efficient building envelopes.

Produced from polystyrene resin with a blowing agent, the foam achieves a closed-cell rate above 99 percent, low thermal conductivity, and very low water absorption. Density grades can be selected to match the required compressive load, with R-values verified to American Society for Testing and Materials (ASTM) standards.

Applications include composite sandwich panels for construction, transportation, and cold storage — wall and roof insulation, underfloor heating, foundation insulation, recreational vehicle bodies, refrigerated truck liners, and cold room walls. The core processes with standard hand tools and CNC routers, and bonds reliably to fiberglass, aluminum, plywood, and steel through vacuum compression molding. Compared with Expanded Polystyrene (EPS), the extruded core offers higher compressive strength and lower water absorption for more stable long-term thermal performance.

RaxPanel: Leading XPS Foam Board Manufacturer

RaxPanel manufactures XPS Foam Board for composite sandwich panels and thermal insulation. Produced at our Hebei facility, the boards combine a high closed-cell rate with low thermal conductivity and reliable compressive strength.

Available in a range of densities and thicknesses, the boards can be matched to the structural load and insulation value each project requires. Typical applications include:

Construction
Cold chain logistics
Marine applications
Transportation

Each order is produced to specification and verified under our quality assurance process, with consistent moisture resistance and stable mechanical performance across the density range.

Contact our engineering team for grade selection, custom dimensions, and a tailored quotation.

Data Sheet
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Parameter	Value	Test Method
General Properties
Material Type	Extruded Polystyrene (XPS)	–
Cell Structure	Closed-cell	–
Closed Cell Rate	≥ 99%	–
Mechanical Properties
Compressive Strength	150 – 700 kPa (varies by density)	ASTM D1621
Flexural Strength	≥ 55 psi	ASTM C203
Flexural Modulus	≥ 1600 psi	ASTM C203
Tensile Strength	≥ 65 psi (vertical)	ASTM D1623
Shear Strength	≥ 35 psi	ASTM C273
Shear Modulus	≥ 400 psi	ASTM C273
Thermal Properties
Thermal Conductivity (λ)	0.028 – 0.035 W/m·K	ASTM C518
Thermal Resistance (R-value per inch)	5.0 ft²·h·°F/Btu (min)	ASTM C518
Operating Temperature	-50 °C to +75 °C	–
Coefficient of Linear Thermal Expansion	3.5 x 10⁻⁵ in/in·°F	ASTM D696
Moisture & Durability
Water Absorption	≤ 0.5% by volume (max)	ASTM C272
Water Vapor Permeance (1 inch)	≤ 1.5 perms (max)	ASTM E96
Dimensional Stability	≤ 2.0% change (max)	ASTM D2126
Physical Properties
Density	30 – 45 kg/m³	–
Fire Performance
Flame Spread	≤ 25	UL 723
Smoke Developed	≤ 450	UL 723

Related Products

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PMI Foam Core

PP Honeycomb Core

PU Foam Core

PVC Foam Core

XPS Foam Core

XPS Foam Core Selection & Engineering Guide

Selecting the right specification for XPS Foam Core comes down to three factors: the structural load the panel must carry, the environmental exposure it will face, and the target thermal performance. The sections below cover the key specification decisions.

💡 Pro Tip: Delamination Prevention Under Thermal Cycling
At RaxPanel, we utilize automated vacuum lamination with high-performance two-component polyurethane adhesives to ensure a bond strength that absorbs differential thermal expansion without micro-delamination.

1. How to Choose the Right Skin Alloy and Thickness

Outer skin selection governs mechanical impact resistance, corrosion barriers, and structural stiffness across different operating environments.

2. How Well Does the Core Insulate and Withstand Heavy Loads?

The core material handles shear stress and maintains thermal R-value insulation across operating temperature ranges:

Performance Metric	RaxPanel Engineering Standard	Application Advantage
Outer Skin Spec	Pre-Painted Aluminum / GRP Sheet (0.3mm – 2.0mm)	High tensile strength and corrosion resistance
Thermal Conductivity	~ 0.020 – 0.038 W/m·K	Consistent R-value insulation & energy savings
Bonding Adhesive	Two-Component Polyurethane / Epoxy Adhesive	Delamination-free performance under freeze-thaw cycles

3. Which Surface Finish Will Protect Your Panels for 20+ Years?

Factory roller coating specifies long-term color stability, UV protection, and resistance against industrial pollutants or marine salt spray.

4. How Fire-Safe and Soundproof Are These Panels?

🛡️ Compliance & Acoustic Isolation:

Fire Safety: Formulations comply with EN 13501-1 Class B-s1,d0 and EN 13501-1 Class B1 building fire safety standards.
Sound Damping: Composite core attenuates noise transmission by 24 dB to 30 dB relative to solid metal sheets.

5. Where Are XPS Foam Cores Most Commonly Installed?

🏢 Commercial & Industrial Buildings

Exterior wall cladding, cleanroom partitions, and insulated roof envelopes.

🚚 Cold Storage & Transport Fleets

Refrigerated truck bodies, cold storage rooms, and RV composite walls.

6. How to Cut, Groove, and Seal Edges During Installation

Panels process easily on-site using standard CNC machinery, routers, or specialized edge profiles for airtight moisture sealing.

Frequently Asked Questions (FAQS)

1. What are the standard panel thicknesses, maximum lengths, and width options available for XPS Foam Cores?

Standard panel thicknesses range from 10mm up to 150mm. Standard widths include 1000mm, 1220mm, and 1500mm, with maximum single-sheet lengths up to 5800mm (5.8m) to fit ocean freight container shipping dimensions.

2. What are the primary engineering benefits of using XPS Foam Cores?

XPS Foam Cores deliver an exceptional stiffness-to-weight ratio, rot-proof moisture resistance, reliable thermal insulation, and dynamic fatigue endurance for high-stress applications.

3. How do these composite panels perform under high humidity and outdoor weathering?

The closed-cell core prevents water logging and condensation absorption, while pre-painted skins provide a 20+ year weatherability barrier against UV degradation.

4. What fire safety ratings and quality certifications do these composite panels meet?

Flame-retardant formulations meet EN 13501-1 Class B-s1,d0 and EN 13501-1 Class B1 fire performance standards. Manufacturing quality is governed under ISO9001 management systems, with raw material performance verified under SGS and CE testing.

5. What surface coating options are available for exterior UV protection?

70% PVDF Fluorocarbon Coating PVDF coating provides a 20+ year exterior weatherability warranty against UV fading and acid rain. FEVE offers high gloss retention, while PE coating is cost-effective for indoor partitions.

6. Can these composite panels be CNC grooved, bent, or edge-sealed on-site?

Yes. Pre-painted skins can be V-grooved at 90° or 135° on the reverse side using standard CNC routers or hand tools, allowing manual edge folding into architectural cassettes without surface paint cracking.

7. How are large panel shipments packaged to prevent freight damage during ocean transit?

Panels are packed with protective PE film on both skins, separated by inter-sheet foam layers, and secured on heavy-duty export wooden pallets or CKD steel crates to prevent shipping damage during 20ft and 40ft container freight.