Automakers and battery manufacturers are constantly striving to improve the safety and efficiency of electric vehicle (EV) batteries. One significant challenge they face is the risk of thermal runaway, which can result in fires and other dangerous situations. In response, companies like Aspen Aerogels are developing innovative solutions to mitigate this risk.

One key aspect of addressing thermal runaway is the use of battery management systems that can detect and control battery conditions to prevent fires before they occur. Additionally, thermal insulation materials, such as those made with aerogels, play a crucial role in limiting damage if thermal runaway does happen.

Traditionally, one drawback of thermal insulation materials is that they add bulk to a battery, reducing its energy density. However, aerogels offer a lightweight solution since they are mostly air, allowing them to limit energy density less than other materials.

COURTESY OF ASPEN AEROGEL

Aspen Aerogels offers thermal barriers that are one to four millimeters thick, which can be stacked between cells in EV batteries. The cost of incorporating these barriers in an EV ranges from $300 to $1,000, depending on the automaker and vehicle model.

The market demand for these materials is rapidly increasing. Aspen Aerogels saw sales grow from $7 million in 2021 to $110 million in 2023, with projections to double again in 2024. To meet this demand, the company is expanding its production capacity.

Currently operating in Rhode Island, Aspen Aerogels plans to build a new facility in Georgia dedicated solely to producing materials for EV batteries. This expansion is supported by a loan from the Department of Energy (DOE) and aims to scale up production by early 2027.

“This loan is critically important to us, to help us with the completion of that project,” says Young, a representative from Aspen Aerogels. The company is focused on meeting the financial and technical requirements to secure the funding and continue its mission to revolutionize EV battery technology.