Overview
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. Synrock's Aerogel Thermal Barrier is engineered as a drop-in thermal barrier between cells and modules to interrupt this propagation pathway.
Compared to traditional insulation pads, our aerogel pad delivers superior flame retardancy, high-temperature resistance, ultra-low thermal conductivity, zero toxic gas emission, waterproof and shockproof performance, lightweight design, and thin-form integration — all in one product.
Verified Test Performance
Independent thermal runaway test results (2 mm aerogel pad between cells): Cell 1 triggered thermal runaway at 874 s. Adjacent cells peaked at 175.4 °C and 109.4 °C at 1044 s — the safety valve did not open. The aerogel pad effectively stopped thermal propagation. This is compared to the 441.3 °C reference temperature seen without protection.
Key Features
- Thermal conductivity: ≤ 0.030 W/m·K at 100 °C; ≤ 0.080 W/m·K at 500 °C
- Available thickness: 0.5–6 mm
- Fire classification: UL 94 5VA + Class A (GB/T 8624)
- Fire test: 1200 °C, 10 minutes, 6 cycles — no burn-through
- Flame insulation: 2 mm pad ≥ 390 °C barrier; 3 mm pad ≥ 450 °C barrier (at 675 ± 15 °C, 20 min)
- Compression performance: 30 ± 5% at 1 MPa; 40 ± 5% at 2 MPa (GB/T 8811)
- Water repellency: ≥ 95% (GB/T 10348)
- Insulation resistance: > 1000 MΩ at 1000 V DC for 60 s
- Voltage withstand: no breakdown, leakage current < 1 mA (GB/T 31838.4)
- RoHS compliant; REACH 219 SVHC compliant; GB/T 30512 automotive compliant
Product Grades
| Grade | Thickness | Fire Level | Application |
|---|---|---|---|
| Low Fire Grade | 0.5–6 mm | Standard | Cell-to-cell separator |
| Mid Fire Grade | 1–6 mm | Enhanced | Module top cover / side wall |
| High Fire Grade | 1–6 mm | 5VA + Class A | Critical barrier, energy storage systems |
Applications
- Electric vehicle (EV) battery pack — cell-to-cell thermal barrier pads
- Battery module between module upper cover / side wall insulation
- Grid-scale battery energy storage systems (BESS) — cluster isolation
- Energy storage container — battery cluster to bulkhead/pipeline insulation
- Hydrogen fuel cell vehicles — hydrogen pipeline high-temperature insulation
| Thermal Conductivity @ 100 °C | ≤ 0.030 W/m·K |
| Thermal Conductivity @ 500 °C | ≤ 0.080 W/m·K |
| Thickness Available | 0.5–6 mm |
| Fire Test (1200 °C) | Pass — no burn-through |
| Flame Rating | UL 94 5VA + Class A |
| Compression @ 1 MPa | 30 ± 5% |
| Compression @ 2 MPa | 40 ± 5% |
| Water Repellency | ≥ 95% |
| Insulation Resistance | > 1000 MΩ (1000V DC,60s) |
| Compliance | RoHS, REACH, GB/T 30512 |
| Test Standard | GB/T 10294, GB/T 8811, GB/T 31838.4 |
| Format | Sheet / Die-cut / Tape |
| MOQ | Contact Us |
| Lead Time | 5–8 weeks (standard) |
| Custom Shapes | Available |