Key Takeaways & Executive Findings
- •• The Ge/SA biomass aerogel with multiple crosslinked networks exhibits excellent flame retardancy (V-0 rating) and thermal insulation (temperature difference ~120 °C across 1 cm). • The SAT/TPEE/EG composite phase change material (CPCM) achieves a high thermal storage density of 811.9 J g−1 and good flame retardancy. • Coupling CPCM with aerogel enables continuous heat absorption, delaying thermal saturation and maximizing insulation duration. • The Ge/SA-CPCM composite maintains top surface temperature at 89 °C after 100 min at 230 °C, offering a promising solution for lithium battery thermal runaway protection.
Abstract
Thermal runaway (TR) is considered a significant safety hazard for lithium batteries, and thermal protection materials are crucial in mitigating this risk. However, current thermal protection materials generally suffer from poor mechanical properties, flammability, leakage, and rigid crystallization, and they struggle to continuously block excess heat transfer and propagation once thermal saturation occurs. This study proposes a novel type of thermal protection material: an aerogel coupled composite phase change material (CPCM). The composite material consists of gelatin/sodium alginate (Ge/SA) composite biomass aerogel as an insulating component and a thermally induced flexible CPCM made from thermoplastic polyester elastomer as a heat-absorbing component. Inspired by power bank, we coupled the aerogel with CPCM through the binder, so that CPCM can continue to ‘charge and store energy’ for the aerogel, effectively absorbing heat, delaying the heat saturation phenomenon, and maximizing the duration of thermal insulation. The results demonstrate that the Ge/SA aerogel exhibits excellent thermal insulation (with a temperature difference of approximately 120 °C across a 1 cm thickness) and flame retardancy (achieving a V-0 flame retardant rating). The CPCM exhibits high heat storage density (811.9 J g−1), good thermally induced flexibility (bendable above 40 °C), and thermal stability. Furthermore, the Ge/SA-CPCM coupled composite material shows even more outstanding thermal insulation performance, with the top surface temperature remaining at 89 °C after 100 min of exposure to a high temperature of 230 °C. This study provides a new direction for the development of TR protection materials for lithium batteries.
1. Introduction
Lithium-ion (Li-ion) batteries, due to their high energy density, long cycle life, and lack of memory effect, are widely used in 3C electronics, aerospace, and new energy fields [1–5]. However, in recent years, incidents of fires and explosions caused by thermal runaway (TR) of Li-ion batteries have occurred frequently [6]. This is because, when a single Li-ion battery undergoes overcharging, short-circuiting, or other abusive conditions, a large amount of heat can be generated in a short period. When the battery temperature reaches 100–130 °C, the separator begins to melt, leading to an internal short circuit, which in turn triggers TR, posing a high risk of fire or even explosion.
What is more concerning is that to meet high energy demands, multiple individual cells are often assembled into a battery module [7]. Once TR occurs in a single cell within the module, the heat may spread to adjacent cells through thermal conduction, potentially causing TR of the entire battery module. Compared to a single cell, the TR of an entire battery module releases more heat and poses a greater hazard, possibly leading to catastrophic fire or explosion accidents [8]. Therefore, it is crucial to develop suitable thermal protection materials to enhance the thermal safety of the entire battery module [9]. Currently, thermal protection materials applied to Li-ion battery TR are mainly divided into two categories [10]: one type is thermal insulation materials, such as aerogels [11, 12]; the other type is heat-absorbing materials, such as phase change materials (PCMs) [13, 14]. These two types of materials delay the accumulation and transfer of heat through insulation or heat absorption, thereby providing more time for cooling and safely handling Li-ion batteries.
In recent years, aerogel materials, as a representative of thermal insulation materials, have been considered the most suitable candidates for thermal protection due to their ultra-low thermal conductivity and high porosity. However, their application is often limited by poor mechanical strength and flammability. On the other hand, PCMs offer high latent heat storage but suffer from leakage and rigidity. This study addresses these challenges by developing a novel composite that synergistically combines a biomass aerogel with a flexible CPCM, inspired by the concept of a power bank, to achieve continuous heat absorption and insulation, thereby significantly enhancing thermal protection for lithium batteries.
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Zaichao Li, Feng Cao, Yuang Zhang, Shufen Zhang, Bingtao Tang (2025). Enhancing Thermal Protection in Lithium Batteries with Power Bank-Inspired Multi-Network Aerogel and Thermally Induced Flexible Composite Phase Change Material. Nano-Micro Letters. https://doi.org/10.1007/s40820-024-01593-0
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Frequently Asked Questions
What is the main innovation of this study?
The study introduces a novel thermal protection material that couples a gelatin/sodium alginate (Ge/SA) biomass aerogel with a thermally induced flexible composite phase change material (CPCM), inspired by a power bank. This design allows the CPCM to continuously absorb heat for the aerogel, delaying thermal saturation and maximizing insulation duration.
What are the key performance metrics of the Ge/SA aerogel?
The Ge/SA aerogel exhibits excellent thermal insulation with a temperature difference of approximately 120 °C across a 1 cm thickness, and achieves a V-0 flame retardant rating, indicating superior fire resistance.
How does the CPCM contribute to thermal protection?
The CPCM, made from thermoplastic polyester elastomer, sodium acetate trihydrate, and expanded graphite, has a high thermal storage density of 811.9 J g−1 and good thermally induced flexibility (bendable above 40 °C). It absorbs heat continuously, delaying heat saturation and enhancing the overall thermal insulation performance.
What is the practical significance of this research?
The developed composite material significantly improves thermal protection for lithium batteries, potentially preventing thermal runaway propagation and enhancing battery safety. It offers a new direction for designing advanced thermal protection materials for high-energy-density battery systems.
What are the limitations of current thermal protection materials addressed by this study?
Current materials often suffer from poor mechanical properties, flammability, leakage, and rigid crystallization. This study overcomes these issues by using a biomass aerogel with multiple crosslinked networks and a flexible CPCM, resulting in improved flame retardancy, thermal insulation, and mechanical flexibility.
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