Lankwitzer Unveils Next-Gen Insulation Material for Battery Cells, Partnering with Tesla for EV Safety Revolution

As electric vehicles (EVs) demand higher energy densities, insulation material for battery cells has become a critical safety component. Lankwitzer’s new solution combines aerogel nanoparticles with UV-curable polymers, creating a flexible yet robust barrier that withstands temperatures exceeding 1,000°C. The material’s thermal conductivity of 0.015 W/m·K is 50% lower than traditional PET films, effectively isolating cells during extreme charging cycles.

Aerogel Composite Technology
Lankwitzer’s proprietary aerogel-resin hybrid matrix forms a three-dimensional thermal barrier, minimizing heat transfer between cells. The material’s nanostructure also enhances flame retardancy, achieving UL94 V-0 certification without halogen additives. Tesla’s 4680 battery cells, now using this insulation, demonstrate a 60% reduction in thermal runaway propagation speed during testing.

UV-Curable Process Advantages
The UV-curable formulation enables rapid manufacturing, with curing times reduced from 20 minutes (traditional epoxy) to 3 seconds. This efficiency boost has already increased Tesla’s Gigafactory throughput by 30%, while energy consumption per cell drops by 70%. Lankwitzer’s automated coating system ensures uniform 0.1mm thickness, eliminating manual errors common in traditional insulation methods.

Sustainability and Scalability
The material’s 92% recycling rate via supercritical CO₂ extraction aligns with EU Battery Passport requirements. Lankwitzer’s new 1,600 m² facility in Osterwieck, set to open in late 2025, will triple production capacity, targeting 50% of global EV battery insulation material market share by 2030.