Flexible Polymer Foams in Thermal Management Technologies: Recent Advances and Applications

ABSTRACT

The increasing demands for advanced thermal management solutions across sectors such as electronics, energy storage, aerospace, and construction have catalyzed the development of flexible polymer foams as multifunctional thermal materials. Unlike traditional rigid insulators or metallic heat spreaders, flexible polymer foams offer a unique combination of low density, mechanical adaptability, and tunable thermal properties, enabling them to conform to complex geometries, accommodate mechanical stresses, and provide efficient thermal regulation. Recent advancements in materials chemistry, structural engineering, and processing technologies have further expanded the capabilities of these foams, incorporating functionalities such as anisotropic thermal conductivity, phase change energy storage, self‐healing, flame retardancy, electromagnetic interference shielding, and intelligent responsiveness to environmental stimuli. This review provides a comprehensive and critical overview of the latest progress in flexible polymer foam technologies for thermal management applications. It begins with a historical perspective on the evolution of polymer foams, tracing key milestones that have led to current high‐performance systems. The paper then systematically explores the diverse applications of flexible foams in thermal insulation, battery thermal management, high‐temperature protection, cryogenic storage, and electronic device cooling, emphasizing recent innovations, performance enhancements, and application‐specific material design strategies. Finally, the review discusses the current challenges limiting broader industrial adoption, including durability under dynamic conditions, sustainability concerns, and the need for standardized testing methods, while proposing future research directions toward intelligent, adaptive, and eco‐friendly thermal management systems.