/Protect from Thermal Runaway Propagation
Illustration of a row of battery cells showing thermal runaway propagation. Three center cells glow red to represent overheating, while surrounding cells remain blue. Thin insulating barrier panels are placed between groups of cells to prevent heat from spreading to neighboring batteries.

Thermal Barriers That Maintain Performance Under Stack Pressure

As prismatic cell formats move toward higher compression to increase energy density, many conventional intercell insulation materials lose thermal resistance under sustained load.

Materials such as aerogel composites and silicone foams can experience measurable performance degradation and dimensional creep at elevated kPa levels. This forces pack designers to add thickness or safety margin to maintain propagation protection.

Compression-Stable Thermal Protection for High-Density Designs

GORE Battery Insulation (GBI) maintains high thermal resistance at >1000 kPa, with <0.5% compressive set. At low thickness, GORE Battery Insulation enables consistent intercell barrier performance without sacrificing stack pressure, volumetric density or long-term stability. Engineered for easy processing, GORE Battery Insulation supports clean, efficient battery module manufacturing.

Performance that Lasts the Battery Lifetime

GORE Battery Insulation is designed to maintain dimensional and thermal stability under sustained stack pressure in high-density cell architectures.

  • <0.5% compressive set under load
  • <50 mW/m·K thermal conductivity
  • <1 mm thickness for space-efficient integration
  • Non-shedding, flexible, die-cuttable and bondable

By maintaining barrier integrity throughout installation and operation, GORE Battery Insulation supports compact pack designs without requiring added thickness or propagation safety margin.

Data Sheet
Diagram showing the formula Thermal resistance (R) = thickness (L) / thermal conductivity (k). Below, a cross-section illustration shows two gray battery cells with a lighter insulation layer between them labeled “L.” Arrows indicate heat flow compressing the insulation layer between the cells.

How Does It Stack Up Against Other Thermal Barriers?

In high-density energy battery packs, intercell material is under sustained mechanical load. As thermal barriers are compressed over time, if thickness is reduced, the risk of heat spreading between cells increases. Maintaining insulation durability and thickness under load is critical to long-term thermal protection.

Comparison table evaluating battery insulation materials across performance criteria including foam pads, rigid inorganic layers (mica), aerogel pads, and GORE Battery Insulation. Rows assess ambient thermal conductivity, thermal resistance under compression, mechanical stability over life, high temperature stability, durability under cycling and swelling, clean handling, ease of integration, and energy density impact. Green checkmarks indicate strong performance, orange dots indicate moderate performance,
Pack-Level Thermal Protection

GORE Battery Insulation helps sustain pack-level thermal performance and mechanical integrity under sustained compression and cycling.

Stress–strain graph comparing deformation behavior of battery insulation materials. GORE Battery Insulation (red) reaches high stress with minimal strain, indicating strong resistance to compression, while Aerogel A (gray) and Aerogel B (black) deform significantly, reaching around 35–40% strain before approaching similar stress levels.
Compressibility Under Load

Compared to aerogels, GORE Battery Insulation exhibits low strain at high pressures.

Chart titled “Simulated Thermal Runaway Test Results” showing average maximum backside temperature (°C) versus applied pressure (kPa) for insulation materials at 2 mm thickness. Cork, Aerogel A, and Aerogel B show increasing temperatures as pressure rises, while GORE Battery Insulation maintains the lowest temperatures, remaining near ~140–160°C even at 1000 kPa, staying within the green safe zone while other materials enter the red high-temperature region.
Real-World Test

In a simulated thermal runaway test, GORE Battery Insulation showed a controlled, stable temperature response across increasing pressure.

Working on a New Battery Design?

Request a sample and validate performance in your application.
 

Product close up of GORE GBI Flat Sheets on green textured background