Making lithium-ion
battery systems safer.

The processing method. LithiumPrevent 200R is suitable for injection molding, while LithiumPrevent 200REX is designed for extrusion.

LithiumPrevent 200REX achieves UL 94 V-0 rating at 2 mm thickness and demonstrates excellent resistance to ignition. UL2596 Torch & Grit performance: withstands 2 cycles at 2 mm, 4 cycles at 3 mm, and 5 cycles at 4 mm.

Refer to SDS. Avoid contamination or contact with acetal resins (POM) to prevent hazardous reactions.

• The price will depend on some variants, such as quantity, project complexity, timeline, etc.
• But Pyrophobic’s LithiumPrevent 200REX is an extrudable intumescent thermoplastic that enables continuous profiles/sheets and feature integration, reducing part count and assembly complexity.
• Additionally, LithiumPrevent 200REX provides intumescent fire protection plus electrical insulation (e.g., UL 94 V-0 at 2 mm; CTI 561; PLC-0 in HAI/HWI), combining multiple safety functions in a single material, which can replace multi-layer stacks (e.g., passive insulators alone).
• We will be glad to set up a quick call for a better understanding of the project and elaborate a specific quote.

• It will depend on some variants, such as quantity, project complexity, address, etc.
• LithiumPrevent 200REX can be supplied as pellets, powder or finished parts.
• We will be glad to set up a quick call for a better understanding of the project and elaborate a specific quote with lead time.

• LithiumPrevent 200REX can be used in cell containment, busbar isolation, and pack-lid defense, and integrated into module housings, spacers, and enclosures as extruded continuous profiles/sheets.
• The LithiumPrevent family targets thermal runaway containment/propagation prevention for EV and ESS/BESS.

Intumescent systems absorb heat and expand to form a protective char layer, creating a thermal and physical barrier that prevents flame from spreading and can seal gaps (key in thermal runaway scenarios).

• Extrusion is a continuous process: molten polymer is pushed through a die to create constant cross-section profiles (e.g., channels, trims, sheets), typically with lower tooling cost and quicker tooling lead.
• Injection molding is cyclic: molten polymer is injected into a closed mold to make complex 3D parts, enabling detailed features. Injection molding is performed under higher pressures.
• These differences guide whether you choose LithiumPrevent 200R (injection-moldable) or LithiumPrevent 200REX (extrudable).

• Mica is a proven, passive high-temperature electrical/thermal insulator (widely used under lids, as barriers, etc.), but is often brittle, labor-intensive to process into intricate shapes, and may raise sourcing/ethical-mining concerns.
• LithiumPrevent 200REX, by contrast, is an intumescent thermoplastic that can be extruded into tailored continuous profiles and expands 2–3x, providing an active char-forming barrier plus electrical insulation (e.g., CTI 561; UL 94 V-0 at 2 mm). This enables design integration (fewer parts/assembly steps) and functional layering that mica alone doesn’t provide.

LithiumPrevent 200REX expansion (reaction) starts at 200 °C.

LithiumPrevent 200REX expands 2 to 3 times their size.

• Forms: Pellets and powder (for extrusion).
• Process: Extrusion for LithiumPrevent 200REX.
• The LithiumPrevent family also supports injection molding via LithiumPrevent 200 and LithiumPrevent 200R.
• Pyrophobic can prototyping via CNC’d blocks and production via injection molding, thermoforming, or extrusion depending on design/economics.

The LithiumPrevent family is developed for thermal runaway containment/propagation prevention, certified by UL 9540A and other fire tests (e.g., UL 94). LithiumPrevent 200REX itself lists UL 94 V-0 (2 mm) and electrical ignition/tracking performance.

Yes, LithiumPrevent 200REX is listed as UL 94 V-0 (2 mm).

• Technical literature explains that intumescent materials generate an expanding, insulating char under heat, whereas passive insulators (e.g., mica, aerogel) primarily resist heat transfer and can require layering/sealing to achieve similar protection.
• LithiumPrevent 200REX provides better passive fire safety solutions because of their active expansion and multi-functionality (thermal + electrical + arc suppression) of its intumescent thermoplastics.

The LithiumPrevent 200REX TDS lists Americas, Europe and Asia-Pacific but you can contact Pyrophobic for other regions too.

• Choose LithiumPrevent 200 or LithiumPrevent 200R (injection-moldable) for complex 3D parts that need integrated features (bosses, clips, fastener seats).
• Choose LithiumPrevent 200REX (extrudable) for linear profiles/sheets (cell spacers, channel sections, lid perimeters) with lower-cost/faster dies and continuous production.

Yes, LithiumPrevent LP200REX is listed as UL 94 V-0 at 2 mm, CTI 561 (ASTM D3638) and HAI/HWI PLC-0, the exact metrics pack teams request for flammability, tracking, and ignition resistance.

Yes, especially when you need an active barrier in an engineered profile. LithiumPrevent 200REX is an extrudable, intumescent thermoplastic that expands 2–3x and carries UL 94 V-0 (2 mm) and CTI 561. LithiumPrevent 200REX provides gap-sealing and electrical insulation in continuous custom profiles that will reduce parts/operations and add active protection.

Yes, but we recommend a minimum thickness of 2 mm for great performance.

Yes, the LithiumPrevent family has been used by companies in the EVs and ESS with outstanding results to prevent and contain thermal runaways in lithium-ion batteries.

Yes, LithiumPrevent 200REX published as UL 94 V-0 (2 mm), CTI 561 and HAI/HWI PLC-0, with expansion rate of 2–3x, and the intended functions such as char barrier, arc suppression and smoke path interruption. LithiumPrevent have been helping a variety of companies to contain propagation when properly integrated.

• Those are excellent passive barriers. LithiumPrevent 200REX doesn’t compete on sub-millimeter films, it complements them by delivering active expansion in engineered plastic geometries (perimeters, channels, busbar isolators) with published UL/CTI/ignition metrics.
• Many packs use both: films/papers in tight gaps and LP200REX profiles where expansion and sealing add value.

• Mica is a solid choice for planar, high-temperature electrical insulation but when you want the barrier to do more than passively endure heat, we recommend LithiumPrevent 200REX.
• LithiumPrevent 200REX is an intumescent thermoplastic designed for extrusion into continuous, custom profiles or sheets, that under heat it starts expanding around 200°C and grows 2–3x, forming an insulating char that can seal gaps, block flame paths, and interrupt arcing/tracking. Functions that mica by itself does not provide.
• In summary, keep mica where you need flat and passive high-temp boards. And use LithiumPrevent 200REX where active expansion and engineered cross-sections (perimeter seals, channels, spacers and busbar isolators) will help contain thermal propagation and reduce part count/assembly steps.

• PyroThin is excellent when your constraint is ultrathin and low-mass passive thermal blocking.
• But LithiumPrevent 200REX does something more: it’s an intumescent thermoplastic for extrusion that expands 2–3x, creating an active, char-forming barrier that can help seal gaps, block flame paths, and interrupt arcing/tracking. Additionally it comes with published electrical safety metrics (e.g., UL 94 V-0 at 2 mm, CTI 561, HAI/HWI PLC-0) that pack engineers often need to cite.
• Because it’s extrudable, you can design continuous, custom profiles or sheets to add purposeful geometry and reduce part count/assembly steps.
• In summary, keep PyroThin where you’re thickness and weight limited, and use LithiumPrevent 200REX where active expansion in an engineered cross-section plus electrical credentials deliver more value to the system.

• Inherently Fire resistant, a higher degree of fire protection than adding a fire retardant to an engineered plastic.
• Highly insulating char which provides a thermal barrier is formed through an endothermic reaction.
• Electrically insulative (high Dielectric Breakdown strength).
• When dealing with lithium battery fire (i.e. class delta fire), this material stays up with rapid rise in temperature by reacting instantaneously.