The best Cushion/Padding Material for LiPo's?

[HacknMod]

I'm building a self-balancing unicycle and I'm strapping batteries to the outside of the vehicle (in a polycarbinate case). When the vehicle falls over, the only thing protecting the large LiPo's on the side (8Ahr, 6s) is 1/8" polycarbinate and some sort of cushioning material between the polycarbonite at the batteries themselves.

What material and what thickness of said material do you recommend I use to prevent the LiPos from being damaged?

Here's some suggestions I've read about online so far:
- 1/8" Neoprene (perhaps encase the batteries in something like this?)
- 1/4" EVA Foam
- 1/2" Polyethylene foam

[dogman]

Thicker neoprene would be ideal, 1/8 is fairly thin. Wetsuits can be cheap at goodwill or similar stores.

Another good material I use inside my battery boxes is 1/4 inch thick neoprene like closed cell foam. Get it by buying a yoga mat. Again, goodwill for it cheap.

If you have 1/2 inch of space to take up, then the cheap closed cell foam anti fatigue/playground mats are great, or a closed cell camping pad for sleeping.

But really, if you have a good box, that's your main protection. Chafing and puncture are the main hazards, and the box prevents puncture. So fit em in nice and snug using anything to prevent chafing and excess movement, cardboard, shipping foam sheets, whatever. Just have the pack rub on soft anything, rather than a screw head or such.

[marty]

http://www.uline.com/
Plank Foam
Provides superior long-term cushioning and support for fragile or heavy items.


Soft Foam
Quickly cushions odd-shaped or delicate products for shipping.


Convoluted Foam Sets
Cut thick convoluted polyurethane foam to the size you need.


Pick And Pack Foam
Create custom foam cushioning without cutting.


Polystyrene Sheets
Economical sheets for short-term blocking and bracing.


Corrugated cardboard is good too.