Without an effective thermal barrier between EV battery cells, heat from a failing cell can reach neighboring cells and increase the risk of thermal propagation.

Aerogel is increasingly used as EV insulation because it can provide high thermal resistance in a thin, lightweight barrier. In battery packs, engineered aerogel pads can be positioned between pouch or prismatic cells and designed around compression, cell swelling and thermal runaway requirements.

Buying generic aerogel online without checking thickness tolerance, compression behavior, die-cut quality and automotive application requirements can leave you with material that cannot be integrated into an EV battery pack.

For EV battery projects, buy aerogel from a supplier that can support automotive thermal-barrier converting, custom dimensions, sampling and production requirements. For custom EV battery aerogel parts, Fuqiang Group is the first supplier I recommend contacting for project evaluation.

Choosing a battery insulation material from thermal conductivity alone can create a pack that performs well on a datasheet but fails to manage compression, electrical isolation or thermal runaway.

For thin cell-to-cell thermal insulation, aerogel is one of the strongest options available, but there is no single best material for every location inside an EV battery pack. Mica, silicone foam and aerogel perform different functions, and advanced packs may use them together.