Lithium Battery Fire Protection Material Selection and Comparison

When designing battery fire protection systems, selecting the right insulation material is critical for ensuring safety and long-term performance. In this article, we compare different aerogel-based solutions for battery thermal management, focusing on their thermal insulation properties, fire resistance, and mechanical stability.

Why Not Use Epoxy Resin Boards?

We do not include flame-retardant epoxy resin boards in this comparison because they cannot provide the effective battery insulation sheet performance required for lithium-ion battery fire and thermal protection.

Pure Aerogel (SiO₂ Aerogel)

• Thermal Conductivity: 0.012–0.02 W/m·K
• Temperature Resistance: ~300–600℃
• Mechanical Strength: Very low, brittle, fragile
• Advantages: Ultra-low thermal conductivity, extremely lightweight
• Disadvantages: Fragile, powdering, difficult to process
• Applications: Laboratory research, thermal coating additives

While aerogel provides outstanding thermal insulation, it becomes unstable at high temperatures and tends to degrade above 300–600℃. This makes pure aerogel sheet materials unsuitable for handling the extreme heat generated during battery thermal runaway (which may exceed 800℃).

Aerogel + Glass Fiber Composite

• Thermal Conductivity: 0.018–0.025 W/m·K
• Temperature Resistance: ~600–800℃
• Mechanical Strength: Medium, flexible
• Advantages: Cost-effective, easy to cut, flexible installation
• Disadvantages: Above 700℃, glass fiber gradually softens or shrinks, causing insulation failure
• Applications: Battery insulation sheet, pipe insulation, general battery barrier applications

According to authoritative studies, lithium-ion battery thermal runaway can reach peak temperatures of 700–1000℃. Under such extreme conditions, glass-fiber-based aerogel sheet solutions may fail, losing their insulation and fire barrier effectiveness.

Aerogel + Ceramic Fiber Composite

• Thermal Conductivity: 0.02–0.03 W/m·K
• Temperature Resistance: ~800–1000℃
• Mechanical Strength: Medium to high, good thermal shock resistance
• Advantages:
• Ceramic fiber remains structurally stable at high temperatures without softening.
• Strong fire resistance and insulation during battery thermal runaway.
• Higher long-term reliability and stability compared to glass fiber composites.
• Disadvantages: Slightly higher cost, more difficult to process
• Applications: Battery enclosure insulation, module partitions, fire insulation panels

Compared with glass fiber composites, ceramic fiber composites offer stronger protection in real-world high-temperature events. For energy storage systems and EV battery packs, the slightly higher cost is offset by significantly improved safety and reliability.

Aerogel + Ceramic Coating (Surface Layer)

• Thermal Conductivity: 0.02–0.04 W/m·K
• Temperature Resistance: ~1000℃ (short-term)
• Mechanical Strength: Medium
• Advantages: Combines insulation with direct flame resistance; withstands fire jetting
• Disadvantages: Complex manufacturing, higher cost
• Applications: Dual-function battery fire protection and thermal insulation layers

Why AUWIN CMC’s LiB AEG Series Is Different

To address the safety pain points of battery thermal management, AUWIN CMC has developed the LiB AEG Series, specifically engineered for lithium-ion battery applications.

1. Unique Manufacturing Process
• Uses proprietary “gradient multi-phase composite technology” with in-situ aerogel generation.
• Avoids ASPEN-related patent costs, providing a more cost-effective Aerogel Thermal Barriers solution.
2. Superior Product Form
• Years of R&D and optimization have made the materials softer, easier to cut, and more flexible for integration into battery modules.
• Perfect choice for high-performance battery insulation sheet and battery fire protection layers.
3. Customization Options
• Available in panels, die-cut sheets, PET film lamination, mica sheet lamination, protective strips, and double-sided adhesive.
• Fully customizable according to customer requirements, ensuring precise fit for battery enclosure insulation needs.

Testing & Samples

You can view related testing videos on YouTube.

For sample requests, please contact: sales@fire-insulations.com

Conclusion

Choosing the right Aerogel Thermal Barriers is essential for lithium-ion battery thermal management. While glass-fiber-based aerogel sheet solutions offer cost advantages, they may fail under extreme battery thermal runaway conditions. On the other hand, ceramic fiber composites provide superior high-temperature resistance, long-term stability, and enhanced battery fire protection.

For industries where safety is paramount—such as EVs and large-scale energy storage systems—aerogel + ceramic fiber composites are the most reliable and future-proof choice.