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One Stop For All Your Aerogel Solutions Needs

  • Custom EV Battery Thermal Protection Aerogel – Tailor-made solutions for superior battery safety and efficiency.

  • Lightweight & High-Performance – 20 times lighter than traditional materials while providing exceptional thermal insulation.

  • Fire & Heat Resistant – Withstands temperatures up to 1200°C, preventing thermal runaway and enhancing EV safety.

  • ISO9001 & IATF 16949 Certified – Guaranteed quality and compliance with global automotive standards.

  • Aerogel Insulation Principle
  • Specifications
  • Material Insights
  • EV Battery Thermal Protection Aerogel has a porous structure that traps air, stopping heat from spreading.
  • Its tiny air pockets block airflow, creating a “zero convection” effect for better insulation.
  • The aerogel’s nano-porous structure acts like countless heat shields, reducing heat radiation.
  • It is fire-resistant and prevents heat from spreading when battery thermal runaway occurs.
  • EV Battery Thermal Protection Aerogel is lightweight, water-resistant, and withstands extreme temperatures.

1. Size & Shape

  • Available in standard sizes like 100mm×100mm, 200mm×200mm, and 300mm×300mm.

  • Custom sizes and shapes (sheets, blocks) to fit different battery pack designs.

2. Thermal Insulation

  • Ultra-low thermal conductivity (<0.021 W/m·K at 25°C) keeps battery temperature stable.

3. Fire Resistance

  • Meets UL94 V0 and Class A fire rating, blocking heat transfer and preventing fire spread.

4. Temperature Resistance

  • Pre-Oxidised Fiber Aerogel: Up to 1000°C (short-term), 400°C (long-term).

  • Ceramic Aerogel: Up to 1200°C (short-term), 800°C (long-term).

  • Glass Fiber Aerogel: Up to 1000°C (short-term), 650°C (long-term).

5. Other Key Features

  • Density: 200-450kg/m³

  • Thickness: 0.5-3mm

  • Compression Stability: <1% change under 2MPa pressure

  • Electrical Safety: Withstands 3000V DC, leakage current <1mA

Ⅰ. Material Composition – What Makes Aerogel Special?

Aerogel is used between battery cells to stop heat from spreading, reducing the risk of thermal runaway (when one overheating cell triggers others). Depending on the specific application, different types of aerogels are used in EV batteries to provide optimal performance.

Key Types of Aerogel Used in EV Battery Protection

1. Silica Aerogel – Best for heat insulation

  • Why it matters: Silica aerogel is one of the lightest solid materials in the world. It has an extremely low thermal conductivity (as low as 0.015 W/m·K), which makes it one of the best materials for preventing heat transfer.

  • How it works: It has a nanoporous structure, meaning that over 90% of its volume is just air trapped in tiny pores. These pores block heat from passing through, making it a great thermal insulator.

2. Organic Aerogel – Flexible and lightweight

  • Why it matters: Unlike traditional aerogels, organic aerogels are soft and flexible, making them easy to fit into complex battery pack designs.

  • How it works: It combines low weight with high insulation performance, providing a balance between flexibility and efficiency.

3. Composite Aerogel – Strong and fire-resistant

  • Why it matters: By combining aerogel with other materials like glass fibers or ceramic fibers, composite aerogels offer better mechanical strength and higher fire resistance.

  • How it works: The reinforced structure improves durability while keeping the aerogel’s insulation properties.

4. Carbon Aerogel – High-temperature insulation

  • Why it matters: Carbon aerogels are strong, conductive, and highly resistant to heat, making them ideal for high-energy-density battery applications.

  • How it works: The unique structure provides excellent thermal insulation while maintaining conductivity, which is useful in batteries that need efficient heat dissipation.

5. Pre-Oxidised Fiber Aerogel – Flexible heat barrier

  • Why it matters: This type of aerogel is flexible and highly fire-resistant, making it ideal for thin and lightweight insulation layers.

  • How it works: The material does not burn easily and can withstand extreme conditions while maintaining good flexibility.

6. Wet-Spun Glass Fiber Aerogel – Strong and heat-resistant

  • Why it matters: Glass fiber aerogels combine mechanical strength with excellent insulation, making them ideal for long-term durability in battery applications.

  • How it works: The glass fibers provide structural support, while the aerogel particles ensure effective heat blocking.

7. Ceramic Fiber Aerogel – Withstands extreme temperatures

  • Why it matters: Ceramic fiber aerogels are designed for extremely high temperatures, making them suitable for the most demanding thermal protection needs.

  • How it works: They remain stable at extreme temperatures and prevent heat transfer effectively.

Ⅱ. Key Properties – Why Aerogel is Essential for EV Batteries

1. Thermal Insulation – Keeps Batteries Cool

  • The nanoporous structure of aerogel limits heat transfer by blocking convection and conduction.

  • This ensures that battery temperatures stay within a safe range, preventing overheating and extending battery life.

2. Fire Resistance – Prevents Thermal Runaway

  • Aerogel is naturally fire-resistant and can block heat transfer in case of a fire.

  • It meets the Class A fire rating, ensuring that flames do not spread easily.

3. Lightweight Design – Reduces Battery Weight

  • Aerogels are 10-20 times lighter than traditional insulation materials, helping to improve the energy efficiency of EVs.

Ⅲ. Structural Advantages – How Aerogel Works

1. Nano-Porous Structure – Blocks Heat Effectively

  • The tiny air pockets inside aerogel trap heat, stopping it from moving through the material.

  • This makes it one of the most effective insulation materials for EV batteries.

2. Composite Strength – More Durable, Better Fire Protection

  • Aerogel combined with materials like glass fiber or ceramic fiber provides extra strength and fire resistance.

Company Profile About Jiepu - PDF
Company Profile - PDF
EV Battery Thermal Protection Aerogel 2

Jiepu EV Battery Thermal Protection

With ultra-low thermal conductivity (0.015 W/mK), our material effectively maintains battery temperature, preventing overheating. Jiepu’s aerogel is thinner and lighter, making battery packs more compact without compromising performance. Plus, its excellent compression resistance ensures it adapts to battery expansion and contraction.

Unlike metal heat sinks or phase change materials, Jiepu’s aerogel insulation is lighter (reducing weight by 30%) and thinner (only 2 mm thick), maximising battery space and improving overall vehicle efficiency. With exceptional durability, it remains stable for over 10 years without aging or leakage, providing a reliable long-term solution for EV battery thermal management.

From Lab to Extreme Conditions

Proven Safety Performance: Our aerogel insulation meets UL94 V0 fire resistance standards and passes the GB 38031 nail penetration test, ensuring high reliability under extreme conditions. In thermal runaway simulations, it extends heat spread delay by ≥15 minutes, providing crucial time for safety measures.

Addressing Key Concerns: Battery safety is essential for EV users. By reducing the risk of thermal propagation, aerogel helps eliminate hidden dangers behind range anxiety, ensuring both performance and peace of mind.

2 EV Battery Thermal Protection Aerogel
1 EV Battery Thermal Protection Aerogel

Aerogel and the Carbon-Neutral Future of EV

Eco-Friendly Material: Aerogel, especially SiOâ‚‚-based types, is recyclable and designed for sustainability. Compared to traditional insulation, its production reduces carbon footprint by 30%, making it a greener choice for EV manufacturers.

Long-Term Benefits: By extending battery life, aerogel helps lower waste and minimises environmental impact. This not only reduces pollution but also supports the shift towards a more sustainable EV industry.

Advanced Thermal Protection for Batteries

Battery Insulation: Jiepu’s aerogel effectively blocks heat transfer within battery cells, modules, and external casings, ensuring stable temperatures.

Fire Protection: It acts as a fire-resistant barrier inside battery systems, enhancing passenger safety by reducing thermal runaway risks.

Optimised Thermal Management: When integrated with cooling systems, it helps maintain battery efficiency and longevity.

4 EV Battery Thermal Protection Aerogel
7 EV Battery Thermal Protection Aerogel

Certified Precision: Jiepu’s Quality Standards in Die-Cutting

At Jiepu, we ensure high-quality die-cutting for EV Battery Thermal Protection Aerogel and other advanced materials. Our services meet ISO 9001, ISO 14001, and IATF 16949 standards, guaranteeing precision, sustainability, and compliance with the automotive industry’s strict requirements.

With our certified processes, we deliver custom die-cut solutions that enhance thermal insulation, fire resistance, and energy efficiency. Whether for EV batteries, automotive applications, or industrial uses, Jiepu’s expertise ensures precision, reliability, and eco-friendly production.

More Aerogel Materials

Jiepu Sample Request & Quotation Process

EV Battery Thermal Protection Aerogel: Sample & Quotation Process

At Jiepu, we make requesting samples and quotations simple and efficient.

For EV Battery Thermal Protection Aerogel, customers provide design drawings, material specifications, and application details. We verify feasibility, produce samples within three days, and conduct strict quality checks before shipping.

Quotation follows a step-by-step cost analysis, covering materials, processing, tooling, and labour. We ensure competitive pricing within 24 hours and provide tiered pricing for bulk orders.

From sample approval to mass production, Jiepu guarantees precision, reliability, and seamless communication to meet your needs.

Is EV Battery Thermal Protection Aerogel Suitable For All EV Batteries?

Now, let me tell you something. When it comes to EV battery safety, we need the best protection. And thermal protection aerogel? It’s one of the best.

It works for lithium-ion batteries—LFP, NMC, you name it. It slows down heat, stops fires, keeps things safe. It even helps solid-state batteries, where controlling heat is just as critical. And for hybrid vehicles? Yes, it’s got them covered too.

But here’s the deal—every battery is different. Every design is unique. That’s why custom solutions matter. And at Jiepu, we deliver precision die-cutting services, shaping aerogel to fit your needs. Because when it comes to battery safety, there’s no room for compromise.

Will Aerogel Insulation Make EV Battery Packs Heavier?

In the EV world, every kilogram counts. And when it comes to thermal protection, aerogel is a game changer.

It’s super light—much lighter than traditional materials like glass fibre or rock wool. In fact, research shows that aerogel-based insulation can cut weight by up to 50% compared to older solutions. That’s 2 to 5 kg saved per vehicle. Less weight, more efficiency.

But here’s the real win—aerogel saves space. Thinner insulation means more room for battery cells, boosting energy density and range. That’s how you get better performance without the extra weight.

And at Jiepu, we make sure your aerogel insulation is cut with precision die-cutting, tailored to your exact needs. Because in EV technology, the right material—and the right fit—make all the difference.

Will Aerogel Insulation Slow Down EV Charging?

Let’s be clear—aerogel insulation does not slow down charging. It’s not blocking the flow of electricity. It’s not interfering with the battery chemistry. What it does is keep the battery at a stable temperature, which actually helps performance.

Now, here’s the key—temperature control matters. When batteries get too hot, charging slows down. Aerogel insulation helps prevent overheating, so the battery stays in the best range for fast, efficient charging. That means better performance, longer battery life.

And the real-world data? Major EV brands already use aerogel insulation, with no negative impact on charging speed. Tests confirm it—thermal protection without compromise.

Will Aerogel Insulation Lose Performance Over Time?

Aerogel insulation stays strong for years. It doesn’t break down easily. It doesn’t absorb moisture. It doesn’t lose its edge.

Why? Its structure is rock-solid. The nano-porous design blocks heat, repels water, and resists aging. Even in tough conditions, it keeps working—no swelling, no sagging, no drop in insulation power.

And here’s the kicker—it outlasts traditional insulation. While other materials wear down, aerogel keeps protecting for a decade or more. That’s why industries trust it, and why EV batteries run safer with it.

Who Competes with Aerogel in EV Battery Insulation?

It’s ultra-light, super-effective, and built to handle extreme heat. But it’s not the only option. So, who’s in the race?

🔹 Traditional Insulation – Rock wool and fibreglass? They insulate well but are heavy. Polyurethane foam? Decent, but burns too easily.

🔹 Ceramic-Based Materials – Ceramic felt and mica sheets? Fire-resistant, sure, but heavier and harder to install.

🔹 Phase-Change Materials (PCM) – Smart tech that absorbs heat, but needs extra insulation to work best.

🔹 Expandable Insulation – Swells under heat, creating a barrier. Great for fire safety, but not as light as aerogel.

🔹 New-Tech Composites – Nanomaterials and silicone blends? Exciting stuff, but still chasing aerogel’s balance of light weight, heat resistance, and durability.

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