Aerogel Fire-Resistant EV & ESS Battery Thermal Insulation Sheet

About AG-ST-GF Aerogel Thermal Barrier Sheet 

In lithium-ion battery systems, thermal runaway propagation remains one of the most critical safety challenges.

Once a single cell fails, the heat released can rapidly transfer to adjacent cells, triggering a chain reaction across the battery pack. Traditional insulation materials such as mica sheets or ceramic papers often struggle to balance thin structure, high-temperature insulation performance and mechanical flexibility at the same time.

AG-ST-GF aerogel sheets are designed to address these challenges by introducing a nano-porous aerogel thermal barrier layer into a flexible composite structure.

Excellent Performance between EV battery cells of Aerogel Thermal Barrier Sheet 

Thermal Runaway Propagation Control in Battery Packs

One of the primary functions of AG-ST-GF is to slow down heat transfer between adjacent cells when a thermal runaway event occurs.

The silica aerogel phase forms a three-dimensional nano-porous structure that traps static air within the material. This structure significantly suppresses multiple heat transfer mechanisms including solid conduction, gas conduction and thermal radiation.

Because of this structure, the material maintains stable insulation performance even under extreme temperatures generated during battery thermal runaway.

Under severe thermal shock conditions, a 2 mm aerogel sheet can maintain a temperature difference exceeding 400 °C, helping delay heat transfer from the failing cell to surrounding cells. By increasing the thermal propagation delay time, the material helps improve the overall safety level of EV battery packs and ESS energy storage systems.

Ultra-Thin Thermal Barrier for High Energy Density Battery Design

Battery pack designers continuously pursue higher energy density, which means the internal space of the pack becomes increasingly limited. Thermal insulation materials must therefore provide effective protection while occupying as little space as possible.

AG-ST-GF aerogel sheets are typically supplied in thicknesses between 1.5 mm and 4 mm, allowing them to be integrated into compact battery pack structures without significantly reducing the internal volume available for cells.

Compared with conventional thermal insulation materials, aerogel composites provide high thermal resistance within a much thinner layer, which helps EV manufacturers maintain pack energy density while meeting thermal safety requirements.

The low density of the aerogel composite also minimizes additional weight in the battery system, an important factor for electric vehicle efficiency.

Mechanical Compliance for Battery Expansion and Vibration

Lithium-ion cells expand and contract during charge-discharge cycles. If the insulation layer is too rigid, mechanical stress may accumulate between cells, potentially affecting cell reliability over long-term operation.

AG-ST-GF uses a composite structure combining aerogel with a flexible glass fiber substrate. This structure provides controlled compression resilience, allowing the material to adapt to small dimensional changes in battery cells.

At the same time, the sheet can absorb vibration and mechanical shock generated during vehicle operation, transportation and system installation. This helps maintain stable contact between cells and insulation layers while reducing structural stress within the battery pack.

High Temperature Resistance and Fire Safety Performance

Battery systems must meet strict fire safety requirements, particularly for electric vehicles and large-scale energy storage installations.

AG-ST-GF is manufactured primarily from inorganic raw materials, providing strong resistance to high temperatures and flame exposure. The material achieves UL94 V-0 flame retardancy, meaning it will not sustain combustion once the ignition source is removed.

Unlike traditional ceramic fiber insulation, the material does not generate loose ceramic dust during handling, making it easier to integrate into automated battery pack assembly processes while maintaining occupational safety standards.

The product also complies with environmental regulations such as RoHS and REACH, supporting global deployment of EV and energy storage systems.

Flexible Processing and Integration into Battery Production

From a manufacturing perspective, insulation materials must be compatible with modern battery pack assembly lines.

AG-ST-GF aerogel sheets have a flat and uniform structure and can be die-cut into customized shapes according to battery cell layouts and module designs. The material can be supplied in sheet form or pre-processed components to match different pack architectures.

This flexibility allows battery manufacturers and system integrators to integrate the material into automated production lines, supporting both prototype validation and large-scale mass production.

Technical Parameter

Typical Applications

AG-ST-GF aerogel thermal barrier sheets are commonly used in:

cell-to-cell thermal insulation in EV battery packs

module-level thermal barriers in lithium-ion battery systems

thermal protection for ESS energy storage modules

battery housing and structural insulation layers

high-temperature electronic equipment requiring flame-retardant insulation

Supply and Customization

Shenzhen Aerogel Technology provides both standard products and customized solutions based on project requirements. Samples can be supplied for validation testing, and the product is available for both small-batch prototype orders and large-scale production supply.