E-Vehicle&Battery Aerogel Insulation Solution
As e-vehicles are becoming more and more popular, we hear about e-vehicle fire accidents often. E-vehicle&battery thermal insulation and fire prevention draw more and more attention. As a leading aerogel material manufacturer in China, our factory provides e-vehicle leading manufacturers with the most efficient customized thermal management and fire prevention solutions.
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Challenges Faced in E-Vehicle&Battery Insulation
As e-vehicles are becoming more and more popular, e-vehicle&battery thermal insulation and fire prevention become big challenges to e-vehicle manufacturers.
E-Vehicle Power Battery Thermal Runaway Safety Hazards
Nowadays, we often hear about safety accidents caused by e-vehicle battery spontaneous combustion, e-vehicle collisions, and fires. In such accidents, battery thermal runaway hazards play a big role. New efficient thermal insulation and fire prevention materials are urgently needed to prevent high-temperature heat from spreading between adjacent battery cells and delay the potential thermal diffusion caused by the battery thermal runaway. Meanwhile, to prevent the heat and fire from spreading into the passenger cabin, it is essential to protect the outer coating of the battery pack from being ignited by high-temperature penetration.
Whole E-Vehicle Heat Insulation& Fire Prevention Problems
Firstly, in winter, e-vehicle battery packs can not work properly when the ambient temperature is too low. New efficient insulation materials are urgently needed for the heat insulation of e-vehicle battery packs to reduce the temperature drop rate.
Secondly, conventional combustible organic foaming thermal insulation materials inside e-vehicles will fuel the fire and produce a lot of toxic smoke, which will directly harm the respiratory and nervous systems of passengers, making it even more difficult for passengers to escape. New inorganic, nontoxic, and fireproof thermal insulation materials are urgently needed to restrain the fire spread, leaving passengers more time to escape.
Lastly, as there is only limited space for thermal insulation materials installation inside e-vehicles, especially inside the battery packs, it is impossible to install complex conventional thermal insulation materials. New ultra-thin, convenient, and efficient thermal insulation materials are urgently needed for e-vehicles.
Aerogel Solution& Products Involved
To solve the core needs of our e-vehicle clients, meet the thermal diffusion protection standards, delay the fire spread, and protect passengers, we have developed a series of products such as different types of battery cell-to-cell thin aerogel thermal barriers, different types of aerogel insulation blankets, panels, customized aerogel tube shells, etc., which build a three-dimensional heat insulation and fire prevention system for cell modules, battery pack, and the whole vehicle.
Products Involved in E-Vehicle&Battery Aerogel Solution
- Extremely low thermal conductivity
- Super thin insulation thickness
- Flame retardant
- Environmentally friendly
With silica (SiO2) aerogel as the core ingredient, and composited with fiberglass/basalt fiber/ceramic fiber, XBR-CS series Aerogel Thermal Barrier Core Sheets can be as thin as 0.1mm but with extremely low thermal conductivity. They are mainly used to produce battery cell-to-cell aerogel thermal barriers to prevent thermal runaways. Thickness and size of the sheets can be customized as required.
- Extremely low thermal conductivity
- Super thin insulation thickness
- Heat resistant: instantaneous thermal shock≤1000℃, long term ≤400℃
- Flame retardant
- Great compression performance as a buffer material between battery cells
- Environmentally friendly
With XBR-CS series Aerogel Thermal Barrier Core Sheets as the core materials, and rubber, polymer and others as the packaging materials, XBR series Thin Aerogel Thermal Barriers are ideal for battery thermal management and now mainly used to prevent thermal runaway of battery cells in new energy vehicle battery packs. Thickness and size of the barriers can be customized as required.
- Insulation Thickness: only 1/5~1/3 of conventional thermal insulation materials
- Easy installation and extremely low thermal bridge
- Applicable Base Surface Temperature: ≤650℃
- Suggested Working Temperature(Long-Term): ≤550℃
- Hydrophobic and flame-retardant
- Non-toxic and environmentally friendly
- Saving you the trouble and cost of industrial waste disposal
XB-HT650 High Temperature Aerogel Insulation Blanket(≤650℃), is our hot-selling star mainly for the thermal insulation demands in medium and high temperatures. It is perfect for the insulation of pipelines and regular-shaped parts or equipment, especially where there is only limited space for insulation material installation.
- Super thin insulation thickness
- Wide Working Temperature Range: -200℃~800℃
- Flexible and strong mechanical performance
- Easy installing operation
- Lifespan same as that of the pipelines and equipment
- Non-toxic and environmentally friendly
XB-BF800 Basalt Aerogel Blanket(-200 to 800℃) is a newly developed high-performance aerogel insulation blanket mainly used for the heat insulation of medium and high temperature pipelines and equipment and can also be used with aluminum foil cover for cryogenic insulation., especially where there are special needs of flexible and strong mechanical performance.
- Insulation Thickness: only 1/5~1/2 of conventional thermal insulation materials
- Applicable Base Surface Temperature: ≤650℃
- Extremely thin insulation thickness, easy installation
- Excellent gas permeability
- Flame retardant and hydrophobic
- Durable and long service life
- Non-toxic and environmentally friendly
XP-HT650 Aerogel Insulation Panel(≤650℃), is a rigid insulation material mainly for thermal insulation on flat, square surfaces. It is mainly applied in integrated insulation panel/board for building construction, medium and high temperature industrial equipment, etc.
- Excellent thermal insulation performance under high or low temperatures
- Easy and convenient installation without manual cutting or wrapping
- Extremely low thermal bridge
- Hydrophobic and flame retardant
- Durable and long service life
- Non-toxic and environmentally friendly
XT-HT650 Aerogel Insulation Tube Shell(≤650℃) is our newly developed insulation material. It can be customized and prefabricated to fit the required pipe sizes and installed directly without any manual cutting or wrapping. It can be applied for the purpose of high temperature or low temperature thermal insulation in various industries like chemical, oil&gas, power generation, etc.
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Solution Steps & Services
Our sales engineers are 24/7 online for you, and in each order step, you will enjoy our professional and considerate services.
Step 1: Inquiry and instant quote (within 24h)
- Contact us about your detailed inquiry requirements, like your project details, required aerogel material specs, quantity, packaging, etc., the more detailed, the better.
- We can offer FOR FREE a sample solution to your project in case you are not sure about the aerogel material you need. You can check the Solution Cases we’ve done for your reference.
- Normally, our sales engineers are 24/7 online. Just submit an inquiry email to us, or directly call us or chat with us online, and we will reply to you within 24h.
Step 2: Sampling(3-10 working days)
- Confirm with us your sample requirements. For new customers, both the sample material costs and delivery costs are borne by the customer; For old customers, sample material costs are borne by us, and delivery costs by the customer. Sampling payment can be done 100% in advance via company or private bank account.
- We will arrange as soon as possible the sample production if it’s not in stock. Normally samples can be ready within 3 days. But for OEM or private label customers, custom sample packaging and labeling may be necessary, so it may take an extra week to prepare them.
- Before the sample delivery by international express, we will take sample photos or videos for your confirmation. International express tracking no. will be sent to you as soon as it comes out, together with the customs clearance documents if you need them. We will follow the whole express delivery process in case of any customs or transportation problems. And we will inform you when your sample has arrived at the nearest express station to you.
Step 3: Sample Testing (time duration depending on you)
- When you receive our aerogel material sample, your feedback is very important to us. Let us know if you have any problems with the sample. We will reply to you within 24h.
- To test our aerogel sample material properly, you may need certain instruments and apparatus and follow our user instructions. As we are 24/7 online, our engineers can help solve your technical problems via phone calls or video calls any time you need.
Step 4: Bulk Order Production(7-25 days)
- After you have tested our sample aerogel material and confirmed your satisfaction, we will come to the bulk order. Invoices or contracts will be sent for your payment by T/T or any other.
- Normally, for bulk order, we can accept at least 30% by T/T in advance and the balance to be made before shipment. But for old or well-reputed customers, different payment policies can be negotiated.
- Normally, bulk order production will be start immediately after you show us the payment bank transaction record and it will take 1-3 weeks to finish. Our sales engineers will follow closely from the beginning to the end. Any problem during production, we will inform you immediately and we can discuss it as soon as possible.
Step 5: Shipping (10-35 days)
- We always make full use of the packing and loading space to help save your transportation costs to the utmost.
- We will book the vessel days in advance from forwarders with rich working experience and strong handling ability, to avoid booking tensions, too troublesome logistics procedures, and before shipment, we will take photos or videos of the packing and loading for your confirmation.
- Transportation documents will be sent to you as soon as it comes out, together with the customs clearance documents if you need them. We will follow the whole shipment process in case of any customs or transportation problems. And we will inform you days before your goods arrived at the destination port.
Step 6: After-sales and Warranty(12 months)
- When you receive our aerogel material bulk goods, your feedback is vital to us. Let us know if you have any problems with the goods. We will reply to you within 24h.
- To install and test our aerogel material properly, you may need certain instruments and apparatus and follow our user instructions. As we are 24/7 online, our engineers can help solve your technical problems via phone calls or video calls any time you need.
- Our aerogel material quality warranty is 12 months. In case any quality failure happens, we will be responsible.
- After 12 months till the service life (normally over 20 years) of our aerogel material ends, if any problem happens with our product, just let us know as soon as possible. We promise to try our best to help solve the problem.
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Contact us now and experience the difference of working with a team of aerogel experts dedicated to your success.
Why Aerogel Solution to E-Vehicle& Battery Insulation
Due to its unique super properties, aerogel is perfect for the thermal insulation and fire prevention of e-vehicles&battery packs. Compared with conventional insulation materials, aerogel insulation materials show their unbeatable advantages when applied in e-vehicles and power batteries:
- A complete system of super thermal insulation and fire prevention
Each of the aerogel insulation materials used in e-vehicles and power battery packs plays an important role in their special application. And together they have formed an unbeatable complete thermal insulation and fire prevention system, which is much better than any single conventional insulation material.
- Unbeatable thermal insulation performance
All the aerogel insulation materials used in e-vehicles and power battery packs are with unbeatable low thermal conductivity, compared with those conventional insulation materials. - Super thin insulation thickness
As the thermal conductivity of each aerogel insulation material applied is extremely low, the insulation thickness is super thin, which can meet the space-saving needs in e-vehicles&batteries, and at the same time, the super-thin insulation thickness can improve the power battery performance. - Flame-retardant and no release of toxic smoke under high temperatures or on fire
Most of the aerogel insulation materials applied are inorganic and release no toxic smoke when encountered with high temperaures or fires. They are environmentally friendly and have passed the REACH&ELV&ROHS certifications.
Quality Assurance of Aerogel Insulation Materials
When you receive our aerogel product, the quality inspection report is along inside, and each piece of the product is quality traceable.
We have a strict and complete quality assurance system including quality management standards, processes, tools, QC staff, and inspection instrument and equipment, etc.
Quality Management Standards We Follow
We’ve been strict in quality management since the very first day of our aerogel career. The quality management system certifications we’ve passed:
- GB/T19001-2016 idt ISO9001: 2015
- IATF16949: 2016
- REACH&ELV&ROHS
- Others required
Our Quality Management Process
We are strict in quality management throughout the whole process from raw material supplier management to final customer feedback.
Supplier Management
Supplier survey and evaluation
Qualified supplier and backup supplier archiving
Supplier performance evaluation and daily supervision
Material Incoming Process
Incoming material warehousing
Incoming material quality inspection and control
Defective material supplier liability confirmation and solution analysis
Production Process
In-process quality audit
Problem analysis and solution by an internal team
Semi-finished and finished product inspection
Sales Process
Finished product shipment process
Third-party warehousing and final customer market feedback
Problem analysis and solution by an internal team
Our Quality Management Tools
We make full use of the five professional management tools below to maintain our aerogel products’ quality at a high level.
APQP
Advanced Product Quality Planning: we do planning, execution, and control from new product project approval to delivery.
FMEA
Failure Mode and Effects Analysis: we do preventive control of the risks in product design and process development.
SPC
Statistical Process Control: we apply statistical techniques to analyze and control a process or production method.
PPAP
Production Part Approval Process: we do capability analysis and variation control of the product manufacturing process.
MSA
Measurement System Analysis: we do capability analysis and variation control of the whole measurement system.
Our Quality Inspection Instrument and Equipment
Basic Knowledge
Aerogel materials are magical future materials, and China is a new rising star in the aerogel industry. The knowledge here below can help you dig deeper into this promising industry as well as our amazing aerogel materials.
Top Silica Aerogel Suppliers in China
15 Record-breaking Magical Properties of Aerogel
Frequently Asked Questions
Discover the Power of Aerogel Today
Have more questions about the magical aerogel materials? Contact us now.