Breaking the 1300°C Barrier: Frebang Nano-Microporous Insulation Sheet Redefines Thermal Safety Standards for EV Batteries and Energy Storage Systems
Created on 08.03
Breaking the 1300°C Barrier: Frebang Nano-Microporous Insulation Sheet Redefines Thermal Safety Standards for EV Batteries and Energy Storage Systems
As the new energy industry rapidly evolves, power batteries and energy storage systems are continuously advancing toward higher energy density, larger capacity, and higher charging/discharging rates. However, thermal safety has become one of the most critical challenges limiting further development.
During thermal runaway events, battery cells can generate extreme temperatures exceeding 1,000°C within seconds. Under such harsh conditions, conventional thermal insulation materials often struggle to maintain structural integrity and effective heat protection.
Frebang's next-generation Nano-Microporous Insulation Sheet provides a breakthrough solution — delivering exceptional temperature resistance up to 1300°C and a high-temperature thermal conductivity over 30% lower than conventional aerogel materials, establishing a new benchmark for thermal runaway protection in EV batteries and energy storage systems.
1. Industry Challenges: Why High-Temperature Insulation Has Become a Critical Bottleneck for Battery Safety
With the continuous evolution toward high-nickel batteries, high-capacity energy storage systems, and higher energy density designs, thermal management requirements have become increasingly demanding.
Extreme thermal runaway temperatures
During battery thermal runaway, flame temperatures can rapidly reach 800–1200°C, far exceeding the operating limits of many traditional insulation materials.
Limitations of conventional insulation materials
- Aerogel blankets:
- Ceramic fiber materials:
Space and weight constraints
Battery packs require insulation materials that provide:
- Ultra-thin design
- Lightweight construction
- High thermal resistance
- Reliable long-term performance
The challenge is achieving "maximum insulation performance with minimum thickness."
Long-term reliability requirements
Energy storage systems are designed for service lives exceeding 10 years. Thermal insulation materials must withstand:
- Continuous thermal cycling
- Long-term aging
- Repeated high-temperature exposure
The performance ceiling of insulation materials directly determines the safety margin of battery systems. The industry urgently requires a new generation of materials capable of combining ultra-high temperature resistance with extremely low thermal conductivity.
2. Technical Breakthrough: The Science Behind Frebang Nano-Microporous Insulation Sheet
With nearly a decade of expertise in advanced nanomaterials, Frebang has developed a new generation of Nano-Microporous Insulation Sheets based on proprietary nanofiber manufacturing technology.
The material integrates:
- Nano-scale ceramic fiber frameworks
- Modified inorganic thermal insulation fillers
- Infrared radiation shielding components
Through precise control of the nano-scale porous structure, Frebang achieves simultaneous breakthroughs in temperature resistance and insulation efficiency.
Nano-Scale Three-Dimensional Thermal Insulation Network
Heat transfer occurs through three primary mechanisms:
- Solid conduction
- Gas conduction
- Thermal radiation
Frebang Nano-Microporous Insulation Sheet effectively suppresses all three heat transfer pathways.
1. Suppressing gas-phase heat conduction
The internal microporous structure is precisely controlled at the nanometer scale, with pore sizes concentrated below the average mean free path of air molecules (~70 nm).
This significantly restricts molecular collisions inside the pores, dramatically reducing gas-phase thermal conduction.
2. Blocking solid heat conduction
The nano-scale ceramic fiber network creates:
- Highly tortuous heat transfer pathways
- Extremely small solid conduction cross-sections
This greatly increases thermal resistance and reduces heat transfer through the solid framework.
3. Reducing infrared radiation transfer
By incorporating high-performance infrared radiation shielding fillers, the material effectively reflects and blocks thermal radiation penetration under high-temperature conditions — addressing one of the major limitations of conventional aerogel insulation.
This three-in-one thermal insulation mechanism enables Frebang Nano-Microporous Insulation Sheet to achieve superior performance in high-temperature environments.
3. Outstanding Performance: Two Breakthrough Advantages Redefining Thermal Insulation
Breakthrough 1: Temperature Resistance Up to 1300°C for Extreme Thermal Conditions
Traditional aerogel blankets typically operate below approximately 650°C, while many ceramic-based insulation materials face challenges maintaining long-term stability beyond 1000°C.
Frebang Nano-Microporous Insulation Sheet achieves:
- Maximum service temperature: up to 1300°C
- Stable long-term operation above 1000°C
Even under severe thermal runaway conditions involving continuous high-temperature flame exposure, the material maintains structural integrity:
✔ No melting
✔ No collapse
✔ No powdering
As an inorganic, non-combustible insulation material, it also provides:
- Low smoke emission
- No toxic gas release under high temperatures
- Enhanced fire safety performance
Breakthrough 2: Over 30% Lower Thermal Conductivity Than Aerogel at High Temperatures
Thermal conductivity is one of the most important indicators for evaluating insulation performance.
At room temperature, aerogel materials demonstrate excellent insulation due to their high porosity. However, as temperature increases, radiation heat transfer becomes increasingly dominant, causing aerogel thermal conductivity to rise significantly.
Frebang Nano-Microporous Insulation Sheet maintains outstanding high-temperature insulation stability:
Temperature | Thermal Conductivity |
25°C | ≤0.025 W/(m·K) |
800°C | ≤0.039 W/(m·K) |
At 800°C, its thermal conductivity is more than 30% lower than comparable aerogel insulation materials.
This means:
- Thinner insulation thickness under the same protection requirements
- Higher safety performance with the same thickness
- Improved space utilization inside battery systems
The higher the temperature, the greater the performance advantage.
4. Application Areas: The Thermal Safety Shield for EV Batteries and Energy Storage Systems
1. Electric Vehicle Batteries: Thermal Runaway Propagation Protection
In EV battery packs, Frebang Nano-Microporous Insulation Sheet can be applied in:
Cell-to-cell thermal barriers
Installed between adjacent battery cells, the material helps:
- Delay heat transfer between cells
- Reduce thermal runaway propagation risks
- Provide valuable response time for thermal management systems
Module covers and battery enclosure insulation
Used in:
- Battery module top covers
- Bottom protection layers
- Pack enclosure insulation
It helps prevent heat transmission toward passenger compartments and surrounding components.
Busbar and wiring thermal protection
Provides effective insulation against high-temperature thermal shock affecting electrical components.
Compared with conventional aerogel pads, Frebang solutions offer:
- Higher temperature resistance
- Lower thermal conductivity
- Reduced thickness
- Lightweight design
Customized structures are available with:
- PET film
- PI film
- Fiberglass reinforcement
Compatible with various battery technologies:
- Blade batteries
- 4680 cylindrical cells
- Pouch cells
2. Energy Storage Systems: A Safety Foundation for Large-Scale Storage
As energy storage systems expand toward MWh and GWh-scale installations, the risk of thermal runaway propagation increases significantly.
Frebang Nano-Microporous Insulation Sheet provides comprehensive thermal protection for:
Battery racks and cabinets
Creates thermal isolation barriers between:
- Battery packs
- Battery cabinets
- Energy storage units
Fire-resistant insulation layers
Applied inside energy storage containers to:
- Delay heat spreading
- Improve fire containment capability
Thermal protection for BMS and electrical components
Helps maintain operational reliability of control systems under extreme thermal conditions.
With excellent temperature resistance and long-term stability, Frebang insulation materials are ideally suited for long-life energy storage applications.
3. Additional High-Value Applications
Beyond battery and energy storage applications, Frebang Nano-Microporous Insulation Sheet is also suitable for:
- Aerospace thermal protection systems
- Marine and defense insulation
- Petrochemical high-temperature pipelines
- Semiconductor thermal equipment
- Rail transportation fire protection systems
It provides an advanced solution for next-generation industrial thermal insulation upgrades.
5. Why Choose Frebang?
As a National High-Tech Enterprise and National-Level Specialized and Innovative “Little Giant” Enterprise, Frebang possesses comprehensive capabilities in nanofiber material development, manufacturing, and application engineering.
Integrated technology capability
From:
- Material formulation
- Nanofiber production
- Structural design
- Engineering application
Frebang provides complete thermal insulation solutions supported by proprietary technologies and intellectual property.
Reliable mass production capability
With manufacturing facilities located in:
- Zhejiang
- Shanxi
- Anhui
Frebang ensures stable production capacity and reliable global supply.
Customized thermal insulation solutions
Solutions can be customized according to customer requirements, including:
- Thickness
- Dimensions
- Reinforcement structures
- Packaging formats
Proven performance in demanding industries
Frebang materials have been validated in high-performance applications including:
- Aerospace
- Defense
- New energy Advanced industrial manufacturing
Conclusion: Advancing the Future of Thermal Safety Through Material Innovation
From functional insulation to extreme thermal protection, Frebang Nano-Microporous Insulation Sheet is redefining the performance limits of high-temperature insulation materials.
With:
- 1300°C temperature resistance
- Over 30% lower high-temperature thermal conductivity compared with aerogel
- Ultra-thin and lightweight design
Frebang provides a reliable thermal safety barrier for electric vehicles and large-scale energy storage systems.
As the global energy industry moves toward safer and more efficient solutions, Frebang continues to advance nanomaterial innovation, helping partners build a more reliable and sustainable energy future.
Contact Frebang for sample testing and technical discussions to explore advanced thermal insulation solutions for next-generation energy systems.
+86 158 3197 8905 （Stanley）
+86 158 3197 8905 （Stanley）
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HQ: Room 907, Tower A, No. 999 Jinzhong Road, Changning, Shanghai, China
Factory Ⅰ：No. 1160, Xinxing 3rd Road
Pinghu Economic & Technological Development Zone, Pinghu, Zhejiang, China
Factory Ⅱ: A06, Tuolingtou Industrial Zone, Yangquan, Shanxi, China
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