Aerogel Technology Reduces the Spread of EV Battery Fires

Aspen Aerogels' technology is being developed to act as a 'firewall' in electric vehicles.

Jan. 15, 2025

2 min read

Aerogels help reduce the impact of EV fires

Inside each electric vehicle (EV) are hundreds or even thousands of lithium-ion cells, which store large amounts of energy. While these cells are among the most efficient ways to store energy, they also pose a danger—occasionally, a cell can overheat and catch fire, potentially igniting others around it.

This risk, particularly from a phenomenon called thermal runaway, as discussed in a recent article from npr, has led the U.S. Department of Energy to provide Aspen Aerogels with a $670.6 million loan to develop solutions to help contain fires in EVs.

One key technology being developed by Aspen Aerogels is aerogel, a lightweight material that excels in thermal insulation. Though not new, the technology continues to expand. Aerogel is made up of about 99% air, with a porous structure composed of silicon and oxygen. Its ability to withstand extreme temperatures makes it ideal for preventing heat from spreading in the event of a battery fire.

In lab tests, aerogel withstood flames of over 2,000 degrees without catching fire or allowing the heat to pass through, essentially acting as a “firewall” that keeps the flames from reaching other cells.

While aerogel doesn't prevent a fire from starting, it offers critical time for passengers to exit the vehicle if the worst happens. The material’s potential extends beyond EVs, with uses in industries like natural gas transport and even space exploration.

To ensure EV safety, experts suggest a multi-pronged approach, including better battery chemistry and predictive data, alongside innovations like aerogels.