Thermal Insulation Materials
Low-conductivity materials slow heat propagation and reduce high-temperature transfer and thermal-runaway risks. Choose felt, foam or sheet materials according to temperature resistance, flexibility, thickness and assembly method.
Thermal Insulation Material Selection Guide
Select thermal insulation materials according to heat-source temperature, insulation requirements, installation space, material form and operating environment. Insulation felt suits extremely high temperatures, foam accommodates tolerances and provides cushioning, while sheets support thin, lightweight and precise installation.
Define the Insulation Goal and Temperature
Determine whether the material must block continuous high temperatures, withstand a short thermal shock or delay battery thermal-runaway propagation. Evaluate the maximum temperature under normal and abnormal conditions.
- Heat-source location and area
- Normal operating temperature
- Maximum abnormal temperature
- Duration of high-temperature exposure
- Direction of heat transfer
- Acceptable cold-side temperature rise
Insulation materials only slow heat transfer and cannot replace a heat-dissipation or cooling system. Do not consider short-term temperature resistance alone; also confirm shrinkage, embrittlement and performance after prolonged heating.
Evaluate Performance and Thickness
Lower thermal conductivity and greater effective thickness generally delay heat penetration. Actual performance must also be evaluated against the temperature difference, contact conditions and available installation space.
- Thermal Conductivity
- Available installation space
- Original material thickness
- Effective thickness after compression
- Hot-side and cold-side temperature difference
- Allowable heat-transfer time
Do not compare thermal conductivity alone. Insufficient thickness, excessive compression or thermal bridges at the edges may reduce insulation performance below the expected specification.
Choose the Material Form
Choose insulation felt, foam or sheet according to temperature resistance, structural tolerances and installation method.
- Felt: Extremely high temperatures, fire protection and large-area coverage
- Foam: Tolerance compensation, cushioning and vibration protection
- Sheet: Thin, lightweight and precision die-cut
- Flat, curved or irregular surfaces
- Need for bending or wrapping
- Need for compression recovery
The three materials differ in more than hardness. Felt emphasizes a high-temperature fiber structure, foam emphasizes compression and recovery, and sheet material emphasizes low thickness, dimensional stability and processing precision.
Check Tolerances and Mounting
When the material is installed between components, housings or battery modules, confirm the gap, assembly pressure and long-term mounting method.
- Mechanical gap and tolerances
- Allowable component pressure
- Required compression
- Long-term recovery
- Adhesive backing or mechanical clamping
- Vibration and displacement risk
Consider insulation foam first when height differences or vibration must be absorbed. Excessive compression reduces effective thickness and insulation performance. When using adhesive backing at high temperatures, confirm the adhesive layer’s temperature resistance.
Assess Processing and Environment
Material form affects cutting precision, positioning efficiency and cleanliness. Select it according to the production method and equipment environment.
- Custom die-cutting and openings
- Manual or automated placement
- Edge integrity
- Dust and outgassing requirements
- High temperature, humidity and thermal cycling
- Flammability and environmental standards
- Contact with oils or chemicals
Insulation felt may shed fibers during cutting, while ultra-soft foam can stretch and deform. Insulation sheets are better suited to precision die-cutting. For high-cleanliness equipment, confirm dust, outgassing and edge condition.
Validate Samples in the Device
After initial material selection, test temperature rise and reliability using dimensions, thickness and mounting methods close to production conditions.
- Actual hot-side and cold-side temperatures
- Heat penetration time
- Material thickness after compression
- Dimensional change after thermal cycling
- Material integrity after high-temperature exposure
- Displacement after vibration
Sample-testing conditions should resemble the actual structure. Heating a small material sample alone does not represent its true insulation performance after installation.
Choose the Right Thermal Insulation Material
Thermal insulation sheets use lightweight, low-conductivity composite materials. Installed between batteries, components or housings, they delay the spread of localized heat to adjacent areas. Their controlled thickness supports openings, custom die-cutting and precise positioning for slim and mass-produced equipment.
Very Low Conductivity
Delays heat propagation between modules.
Lightweight and Thin
Reduces equipment weight and space use.
Flexible Conformity
Fits flat and gently curved surfaces.
Precision Die-Cutting
Supports openings and custom shapes.
Production Ready
Supports fast positioning and automated placement.
Confirm Size and Orientation
Check the outline, openings and installation direction.
Clean the Surface
Remove oil and dust and keep the surface flat.
Align the Sheet
Match the component edges and corresponding openings.
Apply Flat
Bond gradually while avoiding creases and bubbles.
*Avoid creasing or puncturing the material with sharp objects.
Verify the Assembly
Confirm installation and insulation performance.
EV battery modules
Energy-storage battery systems
Mobile communication device
Drone & aircraft
Laptops and tablets
Wearables and VR devices
Thermal insulation foam uses a soft porous structure whose microscopic cells reduce heat transfer. It compresses under low pressure to conform to different heights and provides good recovery and resistance to compression set. It suits equipment requiring insulation, vibration protection and gap filling.
Ultra-Soft Conformity
Fits height differences and irregular surfaces under low pressure.
Insulation and Cushioning
Reduces heat transfer and mechanical shock.
Lasting Recovery
Maintains support after prolonged compression.
Lightweight Structure
Reduces insulation and cushioning weight.
Clean Surface
Suitable for precision electronic environments.
Confirm the Gap
Measure the gap and select the appropriate thickness.
Clean the Surfaces
Remove oil and dust and keep the surfaces dry.
Position the Foam.
Place flat and avoid stretching or deformation.
*Do not stretch the foam during installation, as this may change its dimensions or position.
Apply Even Pressure
Compress evenly to contact both surfaces.
Check Compression
Confirm proper compression and alignment.
*Avoid excessive compression, which reduces effective thickness and insulation performance.
Insulation between battery modules
Automotive electronic devices
Mobile communication device
Drone & aircraft
Wearables and VR devices
Vibration protection for precision electronics
Thermal insulation felt uses a high-temperature fiber structure with low thermal conductivity, heat resistance and aging resistance. It supports continuous high temperatures, short thermal shocks and fire barriers. Its flexible form conforms to flat or gently curved surfaces in industrial equipment and high-temperature automotive areas.
Very High Temperature Resistance
Suits high temperatures and short thermal shocks.
Low Thermal Conductivity
Delays heat penetration through the insulation layer.
Flexible Coverage
Conforms to flat and gently curved surfaces.
Aging Resistance
Maintains material stability during prolonged use.
High Friction
Reduces slipping within the assembly.
Confirm the Coverage Area
Identify the high-temperature area and required insulation range.
Cut to Size
Cut the felt to fit the equipment shape.
Apply the Felt
Fit it evenly along the equipment surface.
Secure and Seal the Edges
Fix the felt and seal the cut edges.
Verify Performance
Check material integrity and test the temperature difference.
Projectors
High-brightness LED modules
Industrial power supplies
EV charging stations
Energy-storage battery cabinets
Drone
Feature Overview
Low Thermal Conductivity
Delay Heat Penetration and Propagation
Low-conductivity materials resist heat flow and reduce the thermal effect of high-temperature areas on nearby components, housings and battery modules.
Thermal-Runaway Barrier
Delay Heat Propagation to Adjacent Modules
Installed between cells or modules, the material delays abnormal heat transfer to adjacent areas, providing response time for monitoring, power disconnection and cooling systems.
Very High Temperature Resistance
Maintain Insulation Under Heat and Thermal Shock
Designed for industrial equipment, engine compartments and fire barriers, maintaining material integrity under continuous high temperatures or short thermal shocks.
Soft Cushioning
Insulate While Absorbing Tolerances and Vibration
A soft, compressible structure conforms to different heights, reduces assembly pressure and absorbs vibration and shock during equipment operation.
Lightweight and Thin
Reduce Insulation Weight and Space
Low-density, thin materials create a thermal barrier while balancing insulation, equipment weight and mechanical layout within limited space.
Thermal Insulation Material Selection FAQs
What is the main difference between insulation felt, foam and sheet?
Insulation felt uses a high-temperature fiber structure for industrial heat and fire barriers. Foam is very soft and compressible for tolerance compensation, cushioning and vibration protection. Sheets provide low conductivity, low weight and controlled dimensions for precision die-cutting and slim electronics.
Does lower thermal conductivity always provide better insulation?
Not necessarily. Actual insulation also depends on thickness, operating temperature, compression, contact area and thermal bridges at the edges. Compare the hot-side and cold-side temperatures in the actual structure instead of relying on one datasheet value.
Which material is best for limiting battery thermal-runaway propagation?
Consider insulation sheets for low heat transfer, thin construction and precision die-cutting between cells. Choose foam when module tolerances and vibration must also be absorbed. Evaluate felt for extremely high temperatures or fire barriers.
Is thicker insulation always better?
No. Greater thickness generally slows heat penetration but also consumes space, may interfere with assembly and changes compression. Select thickness according to the allowable temperature rise, installation gap and equipment weight.
Does greater foam compression improve insulation?
No. Proper compression fills the gap and secures the material, but excessive compression reduces effective insulation thickness and may cause permanent deformation. Set compression according to the product recommendation and actual tolerances.