Aerogel Technologies, LLC has been granted a patent for a new type of ultralight aerogel material that’s waterproof, fireproof, and mechanically durable without relying on environmentally harmful components. The material could have applications across various industries, including electric vehicle (EV) battery cells.
Flexible superinsulation designed for electric vehicle battery packs based on new “dream material”
Made of up to 99+% air by volume, aerogels are the world’s lightest solids — effectively open-celled foams with nanosized air pockets so small that heat cannot pass through them via convection. The material’s unique structure allows for high conductivity and thermal management, which is essential for improving the performance of EV battery cells.
Most forms of aerogel to date have been based on silica, the same substance that makes up window glass. Along with high R-value, silica aerogels exhibit various useful material properties, including hydrophobicity and non-flammability. But like glass, silica aerogel-based materials are incredibly brittle. Aerogel’s polymer has proven to be ten times lighter than plastics yet durable and machinable while being two times more insulating than fiberglass and stable to over 600° F.
Sold under the trade name Airloy H116, the new aerogel is made of a specially engineered polyimide polymer. It can be produced as shaped 3D forms, coherent thin films, or conformal coatings.
Additionally, its lightweight design could help reduce the overall weight of EVs, contributing to increased energy efficiency and extended range — key factors in advancing electric mobility. Furthermore, the material’s durability and adaptability make it suitable for high-stress environments, enhancing its relevance for EV manufacturing.
This breakthrough underscores the growing intersection of material science and clean energy technologies. As industries continue to innovate, materials like this could play a pivotal role in improving energy storage solutions and supporting the global transition to more sustainable transportation systems.
Further research and development will focus on scaling production and optimizing the material for practical applications, including its integration into next-generation EV battery systems.
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