Overview
Flexible Aerogel Insulation is a next-generation thermal management solution specifically engineered for power batteries in electric vehicles (EVs) and energy storage systems. Combining the ultra-low thermal conductivity of aerogel with the flexibility and mechanical robustness of fiber-reinforced composites, this material effectively prevents thermal runaway propagation, maintains optimal battery operating temperatures, and enhances overall system safety.
Key Features
Exceptional Thermal Insulation: Ultra-low thermal conductivity (≤0.020 W/m·K at room temperature), providing reliable protection against heat transfer and thermal runaway.
High Flexibility & Compressibility: Easily conforms to irregular battery cell surfaces, tolerates stack pressure variations, and accommodates battery swelling during charge-discharge cycles.
Thin & Lightweight: Available in thicknesses from 0.5 mm to 3.0 mm, with low density, enabling compact battery pack design without adding significant weight.
Wide Temperature Stability: Maintains performance from -40°C to over 800°C, suitable for both low-temperature preheating and high-temperature barrier applications.
Excellent Flame Resistance: Meets UL94 V-0 rating; self-extinguishing and non-flammable, minimizing fire risk.
Good Compression Recovery: Retains thermal performance after repeated compression cycles, ensuring long-term reliability.
Technical Specifications (Typical)
| Parameter | Value |
|---|---|
| Thickness | 0.5 – 3.0 mm |
| Thermal Conductivity | ≤0.020 W/(m·K) |
| Density | 180 – 220 kg/m³ |
| Continuous Use Temp. | -40°C to 250°C |
| Short-term Peak Temp. | ≤800°C |
| Flammability Rating | UL94 V-0 |
| Dielectric Strength | >4 kV (depending on thickness) |
Applications
Thermal barrier between battery cells (cell-to-cell insulation)
Heat insulation between battery modules and pack casing
Protection against thermal runaway propagation
Insulation for battery cold plates and heating elements
Covering for battery busbars and high-voltage connectors
General Material & Environmental Compliance
✓ UL94 V-0 certified
✓ RoHS (2011/65/EU + 2015/863)
✓ REACH (EC 1907/2006)
✓ ISO14001
✓ ISO45001
✓ ISO 9001:2015 manufacturing facility
Application Case Studies
Case 1 – High-Energy Density EV Battery Pack
Client: Global EV platform developer (China)
Requirement: Must meet GB 38031 (China) thermal runaway propagation requirement – 5-minute warning with no fire/explosion outside pack.
Our Solution: 1mm aerogel pad placed between every two cells, combined with mica sheet on module sides.
Result: During single-cell thermal runaway test, aerogel interlayer maintained structural integrity. No propagation to adjacent cells within 30 minutes. Pack passed certification.
Case 2 – Energy Storage System (Containerized ESS)
Client: European battery storage integrator
Need: Passive fire barrier between battery racks, capable of 800°C exposure for 30 min.
Our Solution: 3mm flexible aerogel composite with aluminum foil facing, installed as vertical barrier.
Result: Temperature on the non-exposed side remained below 200°C. System met local fire code requirements for energy storage cabinet separation.
Why Choose Flexible Aerogel Insulation for Power Batteries?
Enhances Safety: Prevents domino effect of thermal runaway, buying critical escape time.
Improves Battery Life: Maintains uniform temperature across cells, reducing degradation.
Enables Compact Design: Thin profile allows higher energy density in battery packs.
Proven Reliability: Tested for aging, vibration, and thermal cycling per automotive standards.
Packaging & Customization
Available in sheets, rolls, or die-cut shapes. Adhesive backing (double-sided tape or PSA) and edge sealing options are available upon request.
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