China Develops World’s First Aerogel Insulation Material for Lithium Batteries Withstands 1300°C

A research team led by Shen Xiaodong at Nanjing Tech University has successfully developed the world’s first high-thermal-resistance aerogel thermal barrier sheet for lithium-ion batteries capable of withstanding temperatures up to 1,300°C. When one side of this 2.3-mm-thick material is exposed to 1,000°C for five minutes, the temperature on the opposite side remains below 100°C. By overcoming key challenges in efficient supercritical drying—including wet gel drying, pressure control, and cost management—the team has achieved an ethanol recovery rate exceeding 99.5% and reduced raw material costs by more than 50%. To address the brittleness of conventional silica aerogels and their inability to withstand repeated compression during battery charge-discharge cycles, the team drew inspiration from silicone rubber. They selectively “knocked out” certain connection nodes in the nanoporous network and precisely controlled catalyst type, dosage, and solution pH during synthesis. This resulted in an aerogel framework with a loose, flexible long-chain structure that exhibits over 90% elastic compressibility without compromising structural integrity or performance. Through years of iterative development, the team has created a range of high-temperature-resistant aerogel materials—including silicon carbide, silicon nitride, aluminum nitride, and boron nitride—raising the thermal resistance of insulation sheets from 650°C to 1,300°C and extending thermal protection duration to two hours. These materials are now being used in high-temperature kilns and aerospace applications, and have been integrated into power batteries produced by leading companies such as CATL, BYD, Sungrow Power, and Xiaomi Auto.