Engineering grade battery manufacturing architecture
Deep-Tech Partner for Battery Manufacturers

Advanced Thermal Materials for Safer Battery Architectures

Levron Aerogel develops engineered nano-porous thermal solutions for battery cell, module, and pack manufacturers seeking compact, high-temperature, passive thermal protection.

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0.012 W/m·K Thermal Conductivity
1000°C+ Direct Flame Resistance
~2mm Ultra-Thin Profiles
Manufacturing Reality

Where Advanced Materials
Become a Strategic Advantage

Battery manufacturers operate under extreme constraints of packaging density, heat management, and cost. Conventional materials simply take up too much volume or fail under thermal runaway conditions.

To optimize energy density while maintaining safety compliance, engineering teams must evaluate next-generation passive materials that fit seamlessly into modern workflows—without adding bulk to the architecture. Our platform bridges the gap between material science and battery scale-up.

Space Constraints

Energy density demands leave zero room for bulky 10mm conventional insulation.

Thermal Isolation

Single-cell failures must be compartmentalized passively to prevent pack-level disasters.

Manufacturability

Materials must be die-cut, automated, and seamlessly integrated into high-speed lines.

Thermal Runaway Mitigation

Passive Barrier Logic for
Battery Safety Validation

Localized thermal events (700°C–1000°C) require immediate containment. Without robust passive barriers, one cell failure can destroy a megawatt-hour BESS or an entire EV package.

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Initiation Containment

Upon internal short circuit, structural barrier layers slow outward heat flux drastically, giving active safety systems critical response time.

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Compartmentalization

By using low-conductivity (0.012 W/m·K) materials between modules, a thermal event is structurally isolated from neighboring capacity blocks.

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Validation Aware

Our lab testing provides measurable properties (compressive strength, A1 fire rating) ensuring material behaves predictably across UN38.3/UL9540A test scenarios.

High-Energy Density

Why Thin and Compact
Materials Are Critical

In modern EV and ESS battery architectures, mm-level savings translate to massive performance gains.

  • ✓ Architecture Freedom: Reclaim packaging space for active energy materials rather than passive foam.
  • ✓ Thermal Defense: 2mm of aerogel outperforms 10mm of standard mica/wool in dynamic heat tests.
  • ✓ Structural Flexibility: Compressible properties allow materials to act as expansion buffer pads during cell swelling.
Cell 1 (Hot)
HOT CELL CAP (800°C)
2mm Aerogel
Cell 2 (Protected)
ISOLATED (60°C)
Architecture Integration

Thermal Integration Across
All System Layers

We engineer thermal barrier solutions for every structural level, from individual cell wrapping to pack-level acoustic and fire mitigation.

Cell-to-Cell
Module-to-Module
Pack Enclosure

Cell-to-Cell Barriers

Ultra-thin patterned thermal sheets placed directly between prismatic or pouch cells. Functions simultaneously as a thermal blocker and a compressible expansion pad.

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CELL A
CELL B

Module Isolation

Thicker composite barriers (e.g., 3-5mm felt) installed as fireproof bulkheads separating parallel battery modules, drastically reducing module-to-module propagation risk.

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MODULE 01
MODULE 02

Pack Enclosure Fire Defense

Large-format aerogel felts lining the battery housing cover. Prevents outward fire penetration towards the passenger cabin or BESS facility structures.

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STEEL HOUSING
AIR GAP / COOLANT TRAY
Product Portfolio

Advanced Formats for
Battery Form Factors

EV / Prismatic

Thermal Barrier Sheets

  • Compressible architecture
  • Cell-to-cell thermal insulation
  • Custom die-cut profiles
  • Maintains performance under pressure
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Pack / BESS

Levron Aerogel Felt

  • Flexible roll material
  • A1 Fire Class capability
  • Enclosure and perimeter lining
  • Hydrophobic (reels out moisture)
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Custom R&D

Engineered Assemblies

  • Aerogel-mica composites
  • Specialized coatings
  • Pilot prototyping
  • Specific heat mitigation concepts
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Industrial Performance

Technical Metrics Relevant
to Battery Engineers

0.012W
Thermal Conductivity
Blocks heat transfer across module barriers.
1000°C+
Operating Limit
Ceramic composite options survive thermal venting.
90%+
Porosity
Ultra-light mass contribution to the pack.
165°
Hydrophobicity
Zero condensation absorption inside humid packs.
Material Defenses

Breaking the Thickness Efficiency Paradigm

Compare our nano-porous silica platform conceptually against conventional thick insulators and moisture-sensitive foams.

Property Requirement Polymer Foams Mica / Wool Pads Levron Aerogel Platform
High Temp Resistance (>800°C) Melts/Combusts Performs well Yes (up to 1300°C available)
Thickness Efficiency Requires Bulk Requires Bulk Extreme (2mm–5mm)
Moisture Stability Good Poor (Absorbs / Degrades) Superhydrophobic
Thermal Conductivity ~0.035 W/mK ~0.040 W/mK ~0.012 - 0.016 W/mK
Weight Impact Light Heavy Ultra-Light (>90% Air)
Material Translation

From Material Science
to Manufacturing Value

Silica Aerogel Chemistry

50-100nm Porous Structure

Traps air molecules mechanically preventing convective flow.

Methyl Group Modification

Renders the internal surface permanently hydrophobic.

Inorganic Backbone

Silica base structure provides innate non-combustibility.

Battery Manufacturing Value

Compact Design Envelopes

Hit energy-density targets without compromising safety clearance.

Predictable Lifespan

No moisture degradation equals consistent performance over 20+ years.

Validation Success

Predictable flame arrestment ensures higher pass rates on destructive pack tests.

Partner-Ready

How Engineering Teams
Work With Levron

1

Application Review

Detailed architecture discussion and thermal requirement scoping under NDA.

2

Material Spec

Selection of format (sheet vs felt), composite reinforcement, and thickness.

3

Sample & Testing

Evaluation of custom cut samples in customer lab environment.

4

Pilot Scale-Up

Iterative pilot roll-out from our 14,000 m² integrated production line.

Conceptual Relevance

Addressing the Broader
Battery Manufacturing Ecosystem

Ecosystem map background

Automotive EV Packs

CTP (Cell-to-Pack) architectures requiring extreme bottom-shield and cell-barrier protection.

BESS / Energy Storage

Grid-scale high voltage pack fire isolation protecting infrastructure and adjacent racks.

Aviation & Marine

Ultra-lightweight constraints where minimizing mass while surviving thermal runaway is mission-critical.

Corporate Credibility

Deep-Tech Platform.
Industrial Execution.

7Y

7 Years R&D Maturation

Proprietary sol-gel chemistry proven beyond the lab bench.

14K

14,000 m² Integrated Facility

Scaling capacity tailored for high-volume automotive and industrial contracts.

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Engineering Flexibility

We supply advanced chemistry via customized formats, not strict commoditized part numbers.

Levron 14,000 square meter facility
Engineering Knowledge

Evaluation Resources

Datasheet

Thermal Barrier Sheets Specs

View Specifications ↗ Science Guide

Fire Resistance Mechanics

Read the Guide ↗ Verification

Battery Safety FAQ

Explore Answers ↗

Ready to Evaluate Levron Materials
in Your Battery Architecture?

Our engineering team is ready to discuss thermal protection, material specs, and pilot sample integration.

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