Thermal runaway is one of the most critical safety challenges in lithium-ion battery systems.
When a battery cell enters thermal runaway, extreme heat, flame and high-temperature gases can rapidly transfer to adjacent cells and modules. Effective thermal protection materials help interrupt or delay this propagation path by providing thermal insulation, flame resistance and physical separation.
XYFOAMS develops ceramic composite and ceramic-forming silicone foam materials for battery cell, module and pack-level thermal protection.
Our thermal runaway protection materials combine thermal insulation, flame resistance, electrical insulation, cushioning and high-temperature structural stability to meet different battery protection requirements.
Typical applications include:
Cell-to-cell thermal barriers
Cell cushioning and thermal insulation
Module-to-module thermal protection
Battery pack enclosure protection
Battery cover fire protection
Cooling plate insulation and cushioning
High-voltage electrical insulation
Energy storage battery systems
SSG-C and SSG-E are designed to act as thermal barriers within battery systems.
When a cell experiences thermal runaway, the material helps reduce heat transfer and flame propagation toward adjacent cells and components, providing additional protection time for the battery system.
SSG-E is a ceramic-forming silicone foam.
Under normal operating conditions, the material remains soft, elastic and compressible. Under extreme thermal exposure, the silicone foam progressively ceramicizes and forms a rigid, self-supporting ceramic structure.
This transformation allows the material to maintain its barrier function even after exposure to severe heat.
For SSG-E49, the ceramic transformation occurs at approximately 450–500°C, with the resulting porous ceramic structure maintaining good structural integrity.
The fine cellular structure of SSG-E provides low thermal conductivity and thermal insulation.
This makes it suitable for positioning between battery cells, around battery modules and within battery pack structures where reducing heat transfer is critical.
Unlike rigid ceramic boards or traditional thermal barrier materials, SSG-E provides elastic cushioning before thermal exposure.
It can accommodate dimensional tolerances, cell expansion and mechanical movement while maintaining contact pressure.
Customized CFD performance is also available according to application requirements.
SSG-E provides high flame resistance and low smoke characteristics before ceramicization.
The listed SSG-E grades achieve UL94 V-0 flame-retardant performance.
SSG-E combines thermal protection with electrical insulation, making it suitable for battery systems where thermal barriers must also provide electrical isolation.
The listed grades provide dielectric strength of ≥3.0 kV/mm.
SSG-E is designed for demanding temperature environments.
The current product information specifies a recommended operating temperature range of approximately -55°C to +200°C, while the material's thermal protection function extends to much higher temperatures during a thermal event.
SSG-E is designed for lithium-ion battery systems requiring both mechanical cushioning and thermal runaway protection.
Typical applications include:
Pouch cell cushioning
Cell-to-cell thermal barriers
Prismatic cell protection
Module thermal insulation
Module-to-module thermal barriers
Battery pack enclosure protection
Battery cover fire protection
The material can be positioned between cells or around modules to provide cushioning during normal operation and thermal protection during abnormal thermal events.
Large energy storage battery systems contain multiple cells and modules within compact enclosures.
SSG-E can be used as an internal thermal barrier to reduce thermal propagation between neighboring battery components.
Typical applications include:
ESS battery modules
Cell separators
Module thermal barriers
Battery cabinet insulation
Battery enclosure protection
Fire-resistant cushioning pads
SSG-E can be used in EV and transportation battery systems where lightweight thermal protection, cushioning and electrical insulation are required.
Typical applications include:
EV battery packs
Hybrid battery systems
High-voltage battery enclosures
Rail transit battery systems
Battery module protection
The electrical insulation and flame-resistant properties of ceramic silicone foam make it suitable for high-voltage components and electrical enclosures requiring additional thermal protection.
SSG-E can be positioned between pouch cells to provide both mechanical cushioning and thermal insulation.
During normal operation, the foam accommodates cell expansion and dimensional variation.
During a thermal event, the material provides a thermal barrier and progressively ceramicizes under high temperature.
Recommended grades: SSG-E25 / SSG-E40 / SSG-E45 / SSG-E49
The appropriate grade can be selected according to the required compression force and cell structure.
SSG-E can be installed directly between adjacent battery cells.
Its combination of low thermal conductivity, flame resistance and ceramic-forming capability helps reduce thermal transfer between neighboring cells.
For applications requiring higher compression support, higher-density grades such as SSG-E45 and SSG-E49 can be considered.
SSG-E can be used around battery modules to create a thermal barrier between modules or between the module and battery enclosure.
The foam structure provides both insulation and cushioning while maintaining flexibility during assembly.
SSG-E can be used between battery modules and cooling structures where cushioning and thermal protection are required simultaneously.
The elastic foam structure can compensate for dimensional tolerances while providing thermal insulation.
SSG-E can be installed beneath or around battery pack covers to provide an additional thermal protection layer.
Under normal conditions, the foam provides cushioning and insulation. Under extreme heat exposure, it undergoes ceramicization and forms a protective structure.
SSG-C is a non-foamed ceramic composite tape designed primarily for thin, flexible thermal barriers and high-temperature protection.
Its tape structure makes it suitable for locations where installation space is limited and a thin thermal protection layer is required.
Thin and flexible
High-temperature resistance
Flame resistance
Thermal insulation
Electrical insulation
Suitable for customized die cutting
Suitable for multilayer lamination
Cell-to-cell thermal barriers
Module-to-module thermal barriers
Battery enclosure protection
Electrical insulation
Battery pack cover protection
High-temperature structural interfaces
SSG-E is a ceramic-forming silicone foam specifically developed for applications requiring both cushioning and thermal runaway protection.
Before ceramicization, SSG-E behaves as a flexible silicone foam with excellent elasticity, compression performance and thermal insulation.
When exposed to extreme heat, the material progressively transforms into a ceramic-like structure and retains a degree of self-supporting strength after thermal exposure.
This makes SSG-E fundamentally different from conventional silicone foam:
Normal Operation
Cushioning + Compression Resilience + Thermal Insulation + Electrical Insulation
↓
Extreme Thermal Exposure
Ceramicization + Flame Protection + Thermal Barrier + Structural Support
The SSG-E series currently covers four main performance grades: E25, E40, E45 and E49, providing different levels of density and compression force for different battery structures.
Property | SSG-E25 | SSG-E40 | SSG-E45 | SSG-E49 |
|---|---|---|---|---|
Density (g/cm³) | 0.28 | 0.40 | 0.45 | 0.52 |
Compression Stress @25% (kPa) | 40 | 65 | 120 | 170 |
Tensile Strength (MPa) | ≥0.20 | ≥0.30 | ≥0.30 | ≥0.30 |
Elongation (%) | ≥60 | ≥60 | ≥60 | ≥60 |
Compression Set @100°C (%) | ≤5 | ≤5 | ≤5 | ≤5 |
Water Absorption (%) | <5 | <5 | <5 | <5 |
Recommended Operating Temperature (°C) | -55 to 200 | -55 to 200 | -55 to 200 | -55 to 200 |
Flame Rating | V-0 | V-0 | V-0 | V-0 |
Dielectric Strength (kV/mm) | ≥3.0 | ≥3.0 | ≥3.0 | ≥3.0 |
Thermal Conductivity (W/m·K) | 0.07 | 0.07 | 0.07 | 0.07 |
Environmental Compliance | RoHS | RoHS | RoHS | RoHS |
The four grades share the same core thermal, flame-retardant and electrical insulation characteristics, while their density and compression stress increase progressively from E25 to E49.
SSG-E25 — Low Compression Force
Lower density and lower compression stress make E25 suitable for applications where soft cushioning and low compression force are required.
Typical applications:
Pouch cell cushioning
Soft cell separators
Low-load thermal barriers
Electronics cushioning
SSG-E40 — Medium Compression Force
E40 provides a balance between softness, cushioning and mechanical support.
Typical applications:
Cell-to-cell cushioning
Battery module insulation
General thermal barrier applications
Battery enclosure protection
SSG-E45 — Medium-High Compression Force
E45 provides higher compression stress for applications requiring stronger mechanical support while maintaining thermal insulation and flame resistance.
Typical applications:
Battery cell cushioning
Module thermal barriers
Cooling plate support
Higher-load battery structures
SSG-E49 — High Compression Force
E49 is the highest compression grade among the four listed standard grades.
With a density of approximately 0.52 g/cm³ and compression stress of approximately 170 kPa at 25% compression, E49 is designed for applications requiring higher mechanical support and thermal protection.
Typical applications include:
High-load cell cushioning
Cell-to-cell thermal barriers
Module thermal protection
Cooling plate support
Battery pack cover protection
Structural thermal barriers
SSG-E49 also demonstrates approximately 2.8% compression set at 100°C in the company's application data, supporting long-term dimensional stability under compression.
The SSG-E series is designed with progressively increasing compression stress from E25 to E49.
This allows engineers to match the foam's mechanical response to different cell gaps, compression ratios and support requirements.
Compression Stress @25%:
E25: 40 kPa
E40: 65 kPa
E45: 120 kPa
E49: 170 kPa
The grade progression allows the material to be selected according to the required balance between soft cushioning and structural support.
All four listed SSG-E grades provide:
Thermal conductivity: 0.07 W/m·K
Recommended operating temperature: -55°C to +200°C
High-temperature ceramic-forming capability
Flame resistance
Thermal insulation
SSG-E49 has been specifically demonstrated to form a self-supporting ceramic structure at approximately 450–500°C under thermal exposure.
The SSG-E series provides:
UL94 V-0
Dielectric strength: ≥3.0 kV/mm
Low smoke characteristics
RoHS compliance
These characteristics allow SSG-E to combine thermal protection and electrical insulation within the same component.
SSG-E can be supplied and customized according to battery structure and converting requirements.
Grade | Density | Compression @25% | Recommended Position |
|---|---|---|---|
SSG-E25 | 0.28 g/cm³ | 40 kPa | Soft cushioning / low-load thermal barrier |
SSG-E40 | 0.40 g/cm³ | 65 kPa | General cell cushioning / insulation |
SSG-E45 | 0.45 g/cm³ | 120 kPa | Higher-load cushioning / module protection |
SSG-E49 | 0.52 g/cm³ | 170 kPa | High-load cushioning / thermal barrier |
Depending on battery design, SSG-E can be customized in:
Thickness
Width
Length
Density
Compression stress
CFD characteristics
Adhesive backing
Surface treatment
Lamination structure
Die-cut geometry
Customized CFD performance is available for application-specific battery designs.
Material selection should consider:
Cell Type → Cell Expansion → Compression Ratio → Required Compression Stress → Thickness → Thermal Load → Installation Space
SSG-E rolls can be slit into customized widths for automated battery assembly.
SSG-E can be laminated with adhesive layers, films, ceramic composites or other functional materials to create multilayer thermal protection structures.
SSG-E can be converted into customized:
Cell spacers
Thermal barriers
Cushioning pads
Module insulation pads
Battery cover protection pads
Connector protection components
Customized thermal protection gaskets
Based on customer drawings and battery architecture, XYFOAMS can provide customized SSG-E components with specified thickness, geometry, compression characteristics and adhesive structure.
Thermal runaway protection is not simply a matter of selecting the material with the highest temperature resistance.
The correct material depends on:
Cell Structure → Thermal Propagation Path → Compression Requirement → Installation Space → Thermal Load → Required Protection Performance
SSG-C is suitable when a thin, flexible ceramic composite barrier is required.
SSG-E provides a more comprehensive combination of:
Cushioning + Thermal Insulation + Flame Resistance + Electrical Insulation + Ceramic Protection
With four standard grades from E25 to E49, SSG-E allows engineers to select the appropriate compression performance for different battery cell and module structures.
XYFOAMS provides ceramic composite and ceramic silicone foam materials for EV battery and energy storage applications.
Our capabilities cover:
Material Development → Grade Selection → Performance Testing → Lamination → Die Cutting → Customized Components → Mass Production
Request SSG-E technical data, samples or customized die-cut components for your battery thermal protection project.
