Layered aerogel thermal barrier sheets between battery cells showing nano-porous structure with heat-map gradient from hot orange to cool blue
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Product — Thermal Barrier Sheets

Thermal Barrier Sheets for
Compact High-Performance Protection

Advanced aerogel-based sheet materials engineered for compact, high-temperature thermal protection — helping support battery safety, passive fire barrier strategies, thermal isolation, and space-efficient system integration across demanding industrial and energy applications.

0.012
W/m·K conductivity
650°C+
operating resistance
165°
hydrophobic angle
>90%
air by volume
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Product Overview

What Are Levron Aerogel
Thermal Barrier Sheets?

Levron Aerogel Thermal Barrier Sheets are engineered, aerogel-based sheet materials designed for compact, high-temperature thermal protection. Unlike bulk-fill insulation or roll-format materials, these precision-format flat sheets deliver controlled thermal isolation in a format that integrates directly into constrained architectures.

Engineered Sheet Format

Flat, dimensionally controlled sheets designed for precise placement in battery packs, enclosures, compartments, and structured assemblies — not a loose or roll-based product requiring secondary forming or containment.

Aerogel-Based Core Technology

Built on Levron's silica aerogel platform — nano-porous structure with 50–100 nm pores, >90% air by volume, and platform thermal conductivity as low as 0.012 W/m·K. The sheet format inherits the full thermal performance of the aerogel material system.

Compact Thermal Protection

Achieves equivalent thermal resistance to conventional materials at a fraction of the thickness — enabling thermal barrier integration in space-constrained systems where traditional insulation would consume unacceptable volume.

Customizable Material Platform

Sheet thickness, reinforcement type, layer structure, dimensions, and surface treatment can be configured for specific application requirements — from thin cell-to-cell barriers to multi-layer fire protection assemblies.

Thermal barrier sheet cross-section showing aerogel core with nano-porous structure, reinforcement fiber matrix, and heat flow blocking
Why Sheet Format

Why the Sheet Format
Is Strategically Important

In compact thermal systems, material format determines integration efficiency. Sheet-based thermal barriers offer advantages that bulk, granular, and roll formats cannot match in precision-engineered assemblies.

01

Precise Placement Control

Flat sheets can be positioned with millimeter-level accuracy within battery packs, enclosures, and assemblies — enabling targeted thermal isolation exactly where the thermal pathway demands protection.

02

Compact Layered Integration

Sheet materials stack, layer, and interface cleanly with structural, electrical, and thermal management components — supporting multilayer barrier architectures without compromising adjacent system elements.

03

Dimensional Consistency

Uniform thickness across the sheet surface ensures predictable thermal resistance (R-value) mapping. Engineers can calculate thermal performance with confidence — unlike variable-density bulk or fill materials.

04

Structured Assembly Suitability

Sheet format is inherently compatible with die-cutting, adhesive lamination, and mechanical fastening — supporting automated and semi-automated manufacturing workflows in production environments.

05

Multilayer Barrier Strategies

Sheets can be combined in multilayer configurations — alternating aerogel layers with structural, reflective, or composite materials to engineer graduated thermal protection profiles for extreme environments.

06

System Architecture Friendliness

Unlike bulky traditional insulation, thin sheet materials integrate into modern pack, module, and enclosure designs without forcing architectural compromises — preserving energy density, cooling pathways, and structural integrity.

The format advantage is clear: In modern battery packs, ESS cabinets, and industrial enclosures, the precise, flat, dimensionally controlled sheet format enables thermal protection strategies that bulk and roll materials physically cannot support.
Battery & ESS Integration

Conceptual Integration Pathways
for Battery and Energy Storage Systems

Levron Aerogel Thermal Barrier Sheets support customizable integration across multiple zones within battery pack and ESS architectures — each addressing a specific thermal propagation pathway or fire barrier requirement.

Battery pack integration showing thermal barrier sheet placement between cells, modules, and enclosure walls

Cell-to-Cell Thermal Barriers

Thin aerogel barrier sheets placed between individual cells to interrupt direct thermal conduction during cell failure events. The compact sheet form factor minimizes impact on cell spacing and pack energy density.

Thin format Precision placement Propagation delay

Module Separation Barriers

Barrier sheets positioned between battery modules within the pack structure. Designed to contain thermal events at the module level — preventing propagation to adjacent modules and supporting compartmental isolation strategies.

Module-level protection Compartmental isolation

Pack Fire Barrier Assemblies

Thermal barrier sheets integrated into pack-level fire protection assemblies — supporting passive fire barrier architectures between the battery system and vehicle or enclosure structure.

Fire barrier Passive protection Pack-level

Enclosure-Adjacent Protection

Sheet materials lining the interior surfaces of battery enclosures — providing a final passive thermal defense layer between the battery system and the external environment.

Enclosure lining Adhesive-backed Last-line defense

ESS / BESS Compartment Isolation

Thermal barrier sheets deployed within energy storage system cabinets and containers — isolating individual battery racks, modules, or compartments to support thermal containment strategies at the system level.

ESS / BESS Rack isolation Containment

Custom Multilayer Assemblies

Engineered multi-layer configurations combining aerogel sheets with structural, reflective, or composite layers — designed through collaboration to meet specific thermal loads, fire protection requirements, and integration constraints.

Custom composite Co-developed Multilayer
Technical Performance

Engineering-Grade Sheet Material
Performance Specifications

Thermal Barrier Sheet performance is grounded in the Levron Aerogel material platform — delivering measurable thermal, fire, and environmental properties that support engineering evaluation and system design confidence.

Primary Thermal Performance
0.012–0.016
W/m·K platform conductivity

Platform-level conductivity among the lowest of any commercially available solid material. Sheet products with reinforcement deliver applied conductivity of approximately 0.022–0.024 W/m·K — still significantly below any conventional alternative.

Nano-porous silica · 50–100 nm pore structure
Operating Temperature
-200°C to +650°C
standard operating range

Glass wool-reinforced standard configuration. Ceramic wool variants extend the upper operating limit to approximately 1300°C for extreme thermal applications.

Hydrophobicity
165°
water contact angle

Superhydrophobic behavior active up to 650°C. Complete moisture rejection ensures long-term thermal performance stability in humid or sealed environments.

Porosity
90–95%
air by volume

Ultra-high porosity creates one of the lightest solid materials known — enabling thermal protection without meaningful weight penalty in mass-sensitive systems.

Fire Classification
A1 Class
non-combustible (felt platform)

Non-combustible classification at the felt platform level. In controlled 1000°C flame testing, 2cm Levron Felt outlasted 9cm of combined conventional materials.

Specific Heat
~1000
J/kg/K heat capacity

High specific heat capacity contributes to thermal energy absorption during rapid temperature excursion events — the barrier doesn't only block heat, it buffers transient energy.

Compressive Strength
~40 kPa
mechanical resistance

Sufficient structural integrity for compression environments within battery modules, pack assemblies, and structured enclosure configurations.

Service Life
20+ Years
expected durability

Maintains thermal performance, hydrophobicity, and structural integrity over extended service periods. No bacteria growth. No mold. Zero maintenance required.

Macro-to-micro visualization of aerogel nano-porous structure showing 50-100nm interconnected pore network
Material Science

How Nano-Porous Architecture
Enables Sheet-Format Protection

The thermal performance of Levron Aerogel Thermal Barrier Sheets is not achieved through material bulk — it is engineered into the molecular-scale structure of the silica aerogel core, enabling thin sheets to deliver protection that thick conventional materials cannot match.

Silica Network with 50–100 nm Pores

A three-dimensional network of interconnected silica particles creates nano-scale pores smaller than the mean free path of air molecules — physically constraining gas-phase thermal conduction at the molecular level.

Three Heat Transfer Mechanisms Suppressed

Conduction minimized (tortuous solid pathways), convection eliminated (molecular-scale air confinement), radiation scattered (within the pore network). All three heat transfer mechanisms addressed simultaneously within a single thin sheet layer.

>90% Air — Ultra-Light Structure

The material is overwhelmingly composed of trapped air — resulting in exceptionally low density. For sheet-format applications, this means effective thermal protection without meaningful mass penalty per unit area.

Surface Chemistry Delivers Hydrophobicity

Chemical modification of the silica surface creates superhydrophobic behavior (165° contact angle) — ensuring sheets maintain full thermal performance regardless of moisture exposure, humidity, or condensation in sealed systems.

Material Benchmarks

Thermal Barrier Sheets vs.
Conventional Protection Materials

A structured comparison across key performance parameters — helping engineers and procurement teams understand why aerogel-based sheet materials represent a different class of compact thermal protection.

Parameter Stone Wool Sheets Glass Wool Boards Generic Fire Barrier Levron Thermal Barrier Sheet
Thermal Conductivity 0.035–0.045 W/m·K 0.032–0.044 W/m·K 0.04–0.08 W/m·K 0.012–0.016 W/m·K
Thickness for Equal R-value 6 cm 5–6 cm 4–8 cm ~2 cm
Max Operating Temp 500–700°C 400–500°C 300–600°C Up to 1300°C
Moisture Resistance Poor — absorbs water Poor — absorbs water Variable 165° superhydrophobic
Weight Impact High (dense) Moderate Moderate-High Ultra-low (>90% air)
Integration Precision Bulky, rigid Fragile edges Limited flexibility Precise, die-cuttable
Long-Term Stability Degrades with moisture Degrades with moisture Variable 20+ years stable
Fire Performance (1000°C) 5cm fails at 9 min 4cm fails at 9 min Variable 2cm — test stopped

Data represents Levron Aerogel platform and felt-level testing. Comparison values are representative ranges for conventional material classes. Actual sheet product performance depends on specific configurations, reinforcement type, and application requirements.

Levron Thermal Barrier Sheet
Conventional Sheet Materials
Thickness Efficiency
95%
Heat Resistance
90%
Moisture Resistance
95%
Weight Efficiency
92%
Integration Flexibility
88%
Long-Term Stability
90%
Fire Resistance & Environmental Stability

Where Fire Performance and
Moisture Stability Define Value

For thermal barrier sheets deployed in battery, ESS, and fire-critical environments, two properties transform basic thermal insulation into system-level protection confidence: extreme heat endurance and complete moisture independence.

1000°C Direct Flame Resistance Narrative

In controlled laboratory flame testing at 1000°C: 5cm stone wool combined with 4cm glass wool (9cm total conventional material) failed within 9 minutes. A single 2cm layer of Levron Aerogel Felt withstood continuous flame exposure — the test was stopped voluntarily with the material still structurally intact.

2 cm Levron outperformed 9 cm conventional
Why Sheet-Format Fire Barriers Are Different

Thick fire barriers consume space. In battery packs and compact enclosures, a thin sheet material that delivers equivalent or superior fire performance creates direct engineering value — more energy density, more cooling space, less weight, and no compromise on protection.

Superhydrophobic Moisture Stability

Conventional insulation materials absorb moisture over time — losing 50%+ thermal efficiency. Levron Aerogel's 165° superhydrophobic contact angle, active up to 650°C, ensures complete water rejection. In sealed battery environments, this means reliable thermal performance for the full system lifecycle.

1000°C flame test comparison: 9cm conventional materials failed vs 2cm aerogel — test stopped, material intact
🔥

Extreme Heat Endurance

Standard configuration operates from -200°C to +650°C. Ceramic wool variants push upper limits to 1300°C. Non-combustible A1 fire classification at the felt platform level confirms the material never contributes to fire load.

1300°C
maximum operating temperature (ceramic variant)
💧

Complete Moisture Independence

165° superhydrophobic behavior means zero water absorption under any humidity condition. No bacteria growth, no mold formation, no maintenance required. The sheet maintains identical thermal performance from installation through the full service lifecycle.

165°
superhydrophobic contact angle — active to 650°C
Customization & Engineered Solutions

Not a Rigid Commodity Sheet —
A Configurable Protection Platform

Levron Aerogel Thermal Barrier Sheets can be adapted to specific application requirements through engineering collaboration — from sheet thickness and reinforcement type to multilayer assemblies and die-cut formats.

1
Application Requirements Review

Share your thermal protection challenge, system constraints, operating temperatures, space limitations, and integration requirements. Our engineering team evaluates fit and identifies initial configuration options.

2
Material Configuration Design

Select from sheet thickness options, reinforcement types (glass wool, ceramic wool), surface treatments, adhesive layers, and multilayer composite configurations tailored to your system architecture.

3
Sample Evaluation & Testing

Receive configured samples in relevant formats. Conduct your own thermal, fire, mechanical, and environmental testing using your internal protocols and validation requirements.

4
Pilot Production & Scaled Supply

From small-batch pilot runs to volume production — backed by our integrated 14,000 m² facility with full quality control, consistent lead times, and ongoing engineering support.

📐
Custom Thickness

From thin cell barriers to thicker fire-rated panels — configured to match exact thermal performance requirements.

🔗
Multilayer Composites

Aerogel core combined with structural, reflective, or protective layers in engineered configurations.

✂️
Die-Cut Formats

Precision die-cutting for complex shapes, cutouts, and component-specific geometries in production volumes.

🔬
Application Engineering

Co-development support from concept through testing to scaled production — not just a material, a partnership.

Why Levron Aerogel

Not Just a Material Supplier —
An Engineering Partner

7 years of dedicated R&D, 14,000 m² of integrated production capacity, and multi-aerogel chemistry expertise make Levron Aerogel a serious long-term partner for advanced thermal protection development.

7 Years
Dedicated R&D
Thousands of experiments across silica, polymer, metal oxide, carbon, and cellulose aerogel systems.
14,000 m²
Integrated Facility
Complete production — from raw material processing through synthesis to final product formation.
5+
Aerogel Chemistries
Multi-chemistry platform spanning silica, inorganic oxide, polymer, carbon, and bio-based variants.
3
Product Lines
Aerogel Felt, Granules, and Thermal Barrier Sheets — with custom configurations available.
∞
Custom Configurations
Application-specific solutions designed through engineering collaboration with OEMs and integrators.
01

Vertically Integrated Production

Not an outsourced supply chain. Complete manufacturing control from raw chemistry through final product — ensuring quality consistency, IP protection, and reliable supply for demanding applications.

02

Process Innovation Mindset

Continuous process optimization focused on scalability, cost reduction, and material performance advancement — positioning Levron for volume production across industrial, energy, and mobility markets.

03

Engineering Collaboration Model

From initial material exploration through pilot evaluation to scaled supply — Levron works as a co-development partner, not just a transactional supplier. Technical teams engage directly with application engineers.

04

Multi-Market Relevance

Thermal protection solutions relevant across EV battery, ESS/BESS, industrial high-temperature, construction, defense, and specialty applications — supporting diversified supply relationships.

Evaluation Pathway

From Technical Interest
to Scaled Partnership

A structured evaluation pathway designed for engineering teams and procurement professionals who need material confidence before integration commitment.

1

Technical Discussion

Share your application requirements, thermal challenges, and design constraints. Our materials engineering team evaluates fit and recommends initial sheet configurations for your use case.

2

Sample Evaluation

Receive thermal barrier sheet samples in relevant configurations, thicknesses, and formats. Conduct your own thermal, fire, mechanical, and environmental testing using internal protocols.

3

Configuration Optimization

Collaborate on application-specific configurations — custom thicknesses, multilayer composites, die-cut formats, adhesive integration, surface treatments, and packaging specifications.

4

Pilot Production

Small-batch manufacturing run to validate production consistency, quality parameters, and supply chain logistics before committing to volume production.

5

Scaled Supply

Volume production from our integrated 14,000 m² facility — with quality control, consistent lead times, and ongoing engineering support for the lifetime of the partnership.

Technical Resources

Knowledge Center for
Thermal Barrier Sheet Evaluation

Access technical documentation, material data, and educational resources to support your evaluation of aerogel-based thermal barrier sheet materials.

📄
Thermal Barrier Sheet — Product Overview

Comprehensive overview of the Levron Aerogel Thermal Barrier Sheet platform: material properties, format advantages, application concepts, and engineering specifications.

Request Product Overview →
📋
Technical Datasheet — Request

Detailed specifications: thermal conductivity, temperature range, sheet dimensions, fire classification, mechanical properties, and environmental data for engineering evaluation.

Request Technical Datasheet →
📦
Request Sample Kit

Receive physical samples of Levron Aerogel Thermal Barrier Sheets for hands-on evaluation, internal testing, and integration prototyping.

Request Samples →
🔬
Aerogel Felt — Technical Datasheet

Full specifications for the Levron Aerogel Felt platform — the foundational material technology behind the Thermal Barrier Sheet product family.

Download PDF →
📊
Compact Thermal Barrier Explainer

Understanding why thin-format thermal barriers outperform thick conventional materials — the physics, the engineering logic, and the system value of compact protection.

Request Guide →
🛡️
Battery Fire Barrier Guide

Conceptual guide to passive fire barrier strategies in battery pack and ESS architectures — how thermal barrier sheets support safety system design.

Request Guide →
💧
Passive Thermal Isolation Guide

Material science behind passive thermal isolation — including hydrophobicity, nano-porosity, and environmental stability advantages of aerogel-based sheet materials.

Request Guide →
🗓️
Schedule Technical Consultation

Book a one-on-one session with our materials engineering team to discuss your specific thermal protection application requirements and sheet configuration options.

Schedule Call →

Thermal Barrier Sheet — Engineering FAQ

What is the thermal conductivity of Levron Thermal Barrier Sheets?

The Levron Aerogel platform achieves thermal conductivity of 0.012–0.016 W/m·K at the base material level. In applied sheet configurations with reinforcement fibers, conductivity is approximately 0.022–0.024 W/m·K — still significantly lower than any conventional thermal barrier material.

How do thermal barrier sheets differ from aerogel felt?

Thermal Barrier Sheets are precision-format flat sheets designed for direct integration into structured assemblies — battery packs, ESS compartments, and enclosures. They share the same aerogel platform technology as Levron Felt but are configured specifically for sheet-format applications requiring dimensional control, precise placement, and flat-layer integration.

What temperature range can the sheets withstand?

Standard glass wool-reinforced sheets operate from -200°C to +650°C continuously. For extreme-temperature applications, ceramic wool-reinforced variants extend the upper operating limit to approximately 1300°C.

Can sheets be customized for specific thicknesses and dimensions?

Yes. Levron Aerogel Thermal Barrier Sheets can be produced in a range of thicknesses, dimensions, and configurations to suit specific integration requirements. Custom die-cut shapes, adhesive-backed variants, and multilayer composite structures are developed through engineering collaboration.

Are thermal barrier sheets suitable for cell-to-cell battery applications?

Yes. Thin-format thermal barrier sheets are conceptually relevant for cell-to-cell thermal propagation mitigation in battery packs. The compact profile minimizes impact on cell spacing, while the aerogel core delivers thermal resistance significantly exceeding conventional alternatives at equivalent thickness.

How does hydrophobicity affect sheet performance in sealed systems?

In sealed battery packs and enclosed ESS environments, moisture ingress can degrade conventional insulation materials by 50%+. Levron's 165° superhydrophobic surface completely rejects water — ensuring consistent thermal protection throughout the system's lifecycle regardless of humidity conditions.

What is the minimum order quantity for samples?

Levron supports engineering evaluation programs starting with small sample quantities. Contact our team to discuss your evaluation requirements — we structure sample programs to match your testing protocol and timeline.

Can multilayer composite sheets be developed?

Yes. Levron can engineer multilayer configurations combining aerogel core sheets with structural, reflective, adhesive, or barrier layers to meet specific thermal loads, fire protection requirements, and mechanical integration constraints. These are developed through co-engineering collaboration.

Get Started

Ready to Evaluate Levron Aerogel
Thermal Barrier Sheets?

Choose the engagement pathway that matches your role and evaluation stage. Our team supports engineers, procurement professionals, OEM integrators, and product developers.

For Engineers

Discuss material capabilities, thermal performance data, sheet configurations, and integration concepts with our engineering team.

Talk to an Engineer

For Procurement

Request quotes, discuss supply terms, lead times, and volume pricing for thermal barrier sheet materials.

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For OEM / Integrators

Initiate a pilot project — from custom configuration through sample evaluation to scaled production partnership.

Start a Pilot Project

For Technical Buyers

Request the full technical datasheet with thermal conductivity, temperature range, fire classification, and engineering specification data.

Request Technical Datasheet

For Product Developers

Request physical samples of thermal barrier sheets for hands-on evaluation, prototyping, and internal testing.

Request Sample
Thermal Barrier Sheets Advanced aerogel-based sheet materials for compact thermal protection
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