A precision-engineered aerogel thermal barrier designed specifically for EV battery modules and grid-scale energy storage systems — delivering critical cell-to-cell thermal runaway protection in the thinnest possible form.
As lithium-ion battery energy density increases, so does the risk of thermal runaway — a chain reaction that, once initiated, can spread rapidly from cell to cell. AeroTech's Aerogel Battery Insulation Pad (AT-BP Series) is engineered as a drop-in thermal barrier between cells and modules to interrupt this propagation pathway.
Based on our core silica aerogel technology, the pad offers an unmatched combination of ultra-low thermal conductivity, extremely thin profile, robust mechanical compression resistance, and full electrical insulation. It can be supplied in custom-cut shapes matching your module geometry.
In a typical 72 kWh EV battery pack, a single cell thermal event can reach temperatures exceeding 800 °C within seconds. Conventional foam or polymer separators begin to degrade above 150–200 °C. Our aerogel pad maintains its structural and thermal integrity up to 1000 °C, providing the critical time window needed for BMS intervention or passenger evacuation.
| Grade | Thickness | Max Temp. | Cell Format |
|---|---|---|---|
| AT-BP01 | 1 mm | 800 °C | Prismatic / Pouch |
| AT-BP02 | 2 mm | 1000 °C | Prismatic |
| AT-BP03 | 0.5–5 mm | 1000 °C | Custom / All Formats |
| Thermal Conductivity | ≤ 0.025 W/m·K |
| Max Instantaneous Temp. | 1000 °C |
| Operating Temperature | -40 °C to +300 °C |
| Standard Thickness | 0.5 / 1 / 2 / 3 / 5 mm |
| Compressive Strength | ≥ 0.3 MPa @ 10% strain |
| Volume Resistivity | > 10¹² Ω·cm |
| Dielectric Strength | > 5 kV/mm |
| Outgassing | Low (battery compatible) |
| Density | 200–350 kg/m³ |
| Standard Sheet Size | 500 × 500 mm (custom) |
| Format | Sheet / Die-cut / Tape |
| MOQ | Contact Us |
| Lead Time | 3–5 weeks (standard) |
| Custom Shapes | Available |