How MPP Foam Can Protect Your EV Battery Pack from Thermal Runaway with Aerogel Felt

Electric vehicles (EVs) are becoming more popular and affordable as the demand for clean and sustainable transportation grows. However, EVs still face some challenges in terms of battery performance, safety, and longevity. One of the most serious issues is thermal runaway, a phenomenon where a battery cell overheats and catches fire, potentially spreading to other cells and causing a catastrophic failure of the battery pack.

Thermal runaway can be triggered by various factors, such as overcharging, short circuiting, mechanical damage, or external heat sources. Once it starts, it is very difficult to stop or contain, as the battery cells release flammable gases and molten materials that can ignite other cells or components. Thermal runaway can result in severe consequences, such as fire, explosion, injury, or death.

To prevent or mitigate thermal runaway, EV battery manufacturers and users need effective solutions that can provide thermal insulation, protection, cushioning, and gasketing for the battery pack and cells. One of the most promising solutions is MPP foam, a microcellular polypropylene foam that has excellent properties for EV battery applications.

MPP foam is a lightweight, flexible, and resilient material that can conform to the shape and size of the battery cells and modules. It can fill the gaps and spaces between the cells and provide a uniform pressure distribution that prevents delamination and deformation. It can also absorb shocks and vibrations that can damage the cells or cause electrical disconnections.

MPP foam has a high thermal stability and low thermal conductivity that can reduce heat transfer and prevent overheating of the cells. It can also act as a thermal barrier that can slow down or stop the propagation of thermal runaway from one cell to another. Moreover, MPP foam has a high fire resistance and self-extinguishing ability that can prevent or limit the spread of flames and smoke.

One of the unique features of MPP foam is that it can be combined with aerogel felt, a super-insulating material that has extremely low thermal conductivity and high porosity. Aerogel felt is made of silica aerogel, a solid material that consists of 95% air and 5% silica. Aerogel felt can trap air molecules in its nano-sized pores and create a near-vacuum environment that minimizes heat transfer.

By laminating MPP foam with aerogel felt, a composite material with enhanced thermal insulation and protection properties can be obtained. This composite material can provide an additional layer of safety and performance for the EV battery pack and cells. It can also reduce the weight and thickness of the battery pack, which can improve the energy density and efficiency of the EV.

MPP foam with aerogel felt is a proven solution that has been successfully applied in various EV battery projects around the world. For example, China Fuzhou Fuqiang Precision Co., Ltd., a leading manufacturer of EV battery components and systems, has used MPP foam with aerogel felt to protect their EV battery packs from thermal runaway. They have reported positive results in terms of thermal management, fire prevention, shock absorption, noise reduction, and cost saving.

If you are interested in learning more about MPP foam with aerogel felt and how it can benefit your EV battery applications, please contact us today. We are happy to provide you with more information or send you a sample of our product. We look forward to hearing from you soon.