Next-Generation Thermal Runaway Protection Materials

Our Ultra-thin Microporous Insulation Panel delivers exceptional fireproof and thermal insulation performance, providing efficient thermal insulation and thermal runaway protection for EV batteries and Energy Storage Systems (ESS). Compared to aerogel solutions, our product offers superior temperature resistance and thermal stability, much lower thermal conductivity at high temperatures, and unique advantages such as smoke-free emission.

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Why Microporous Insulation Matters in Thermal Runaway Protection?

Thermal runaway occurs when internal battery chemical reactions cause a rapid temperature increase, initiating a chain reaction. This phenomenon can result in overheating, smoke, fire, or explosion, posing substantial risks to personal safety and property. Furthermore, thermal runaway may propagate to adjacent battery cells, potentially expanding into larger-scale fires.

Microporous insulation is crucial for thermal runaway protection, it provides exceptional thermal resistance in an extremely thin, lightweight form. Its microporous structure and the use of opacifiers minimizes all three modes of heat transfer - conduction, convection, and radiation - delaying the spread of excessive heat between battery cells. This critical delay helps contain a thermal event within a single cell, preventing it from spreading through the entire battery pack and allowing more time for safety systems to activate.

Our microporous insulation barriers provide critical thermal runaway protection for battery systems:

Thermal Insulation Performance Multiple Times Superior to Aerogel Blankets

Microporous insulation materials deliver multiple times superior thermal performance compared to aerogel blankets at elevated temperatures, while offering higher temperature resistance.

Excellent Flame-retardant Performance

Inorganic, non-combustible material rated UL 94 V-0.

Microporous insulation

Good Mechanical Performance

Its mechanical performance as a compression pad helps to maintain the correct pressure on the battery pack. The compression performance of our materials can be precisely tuned through recipe adjustments and density control. Additionally, compression characteristics can be enhanced by compositing with various elastic materials

Microporous insulation

Dielectric Stability and Isolating

Our microporous insulation barriers provide superior dielectric and aging resistance.

Our naked panels withstand 3500V DC with a maximum leakage current of ≤ 0.1 mA, ensuring high dielectric insulation quality.

Thin and Lightweight

We offer lightweight, thin battery system solutions with material thicknesses down to 0.8 mm. Our products support highly customizable dimensions; meeting demands for both weight reduction and tailored configurations.

Robust and Environmentally Friendly

Our solutions are not influenced by normal operating conditions and not impacted by humidity. No harmful substance emissions and no smoke in case of fire.

Microporous insulation

Thermal Runaway Application Scenarios

Our microporous insulation products effectively contain thermal runaway propagation in electric vehicles (EVs) and energy storage systems (ESS). Engineered for demanding applications, our thermal runaway barriers offer customizable performance through solution-based design, with primary applications including:

  • Cell-to-cell thermal runaway propagation in EV and ESS
  • Battery pack and module barriers

Why Partner with Unicorn Insulations

Expert of Microporous Insulation Materials

From formulating to part manufacturing, our cell-to-cell (C2C) barriers are designed, engineered, and produced by ourselves.

Trusted, Proven Record of Projects in EV and ESS

Our microporous insulation panels for cell-to-cell barriers are in volume production for major players in the market.

Engineering Support

Our solutions are tailored to meet your specific needs, offering engineered thermal management design and customized sizes for battery platforms.

Fast Response and Deliveries

With manufacturing facilities in China and Malaysia, we maintain strong production capabilities to guarantee timely and reliable deliveries.

RELATED PRODUCTS

TT 1000 classic LB

TT 1000 classic LB is an ultra-thin microporous insulation panel with customized outer coverings. It is an ideal choice for creating excellent thermal insulation and fire protection properties for...

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TT 1000 classic LB is an ultra-thin microporous insulation panel with customized outer coverings. It is an ideal choice for creating excellent thermal insulation and fire protection properties for lithium-ion batteries. Compared to aerogels, our product offers superior temperature resistance and thermal stability, lower thermal conductivity at high temperatures, and the advantage of being smoke-free.

Due to its best-in-class thermal insulation and fireproofing properties, TT 1000 classic LB is a new-generation thermal barrier that replaces aerogels and other traditional products in preventing thermal runaway in electric vehicles and Battery Energy Storage Systems (BESS).

Typical applications:

  • Cell-to-cell thermal runaway protection
  • Fire protection and thermal insulation for packs and modules

Product options:

  • Naked panel
  • PET film encapsulation
  • Laminated with mica
  • Laminated with foam or silicone frame
TT 1000 classic LB
TT 1000 classic LB
TT 1000 classic LB
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