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<p>Lithium-ion batteries are core power sources for electric vehicles. However, they face serious safety concerns associated with thermal runaway. In this study, a novel intumescent flame-retardant epoxy resin (IFRE) was developed and used as a firewall between pouch batteries to mitigate thermal runaway propagation (TRP). The IFRE is based on epoxy resin, with ammonium polyphosphate as the acid source, pentaerythritol as the carbon source, melamine as the gas source, nano-aluminum hydroxide and attapulgite as fillers, and modified with SiB₆ and expanded graphite. The synthesized IFRE4 sample exhibits excellent flame-retardant properties. In the large plate test, the backside temperature of steel plate coated with IFRE4 was only 158.6 ℃ after 15&#xa0;min of flame impingement. It achieved a V-0 rating in the vertical burning test, with a limiting oxygen index of 35.7%. In the cone calorimeter test, its peak heat release rate, total heat release, peak smoke production rate, total smoke production, and char residue rate are 271.80 kW/m<sup>2</sup>, 47.25 MJ/m<sup>2</sup>, 0.089 m<sup>2</sup>/s, 16.63 m<sup>3</sup>, and 39.23%, respectively. This IFRE releases non-combustible gases at high temperatures, forms a dense porous char layer, expands its volume to 8 times the original, and significantly increases thermal resistance between batteries. When used as a fire wall between 10Ah pouch batteries, a 4-mm thick material can stop the TRP, and the maximum temperature of battery is reduced by approximately 50%, reaching only 348 ˚C. This study provides a novel material for suppressing TRP in battery packs in the future, which can effectively enhance battery safety.</p>

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Mitigating Thermal Runaway Propagation of Pouch Batteries by Intumescent Flame-Retardant Epoxy Resin Plates

  • 期刊论文

  • 发表日期：

    2026年7月28日

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  • Fuhao Yang,
  • Luyao Zhao,
  • Minxue Zheng,
  • Mingyi Chen

摘要

Lithium-ion batteries are core power sources for electric vehicles. However, they face serious safety concerns associated with thermal runaway. In this study, a novel intumescent flame-retardant epoxy resin (IFRE) was developed and used as a firewall between pouch batteries to mitigate thermal runaway propagation (TRP). The IFRE is based on epoxy resin, with ammonium polyphosphate as the acid source, pentaerythritol as the carbon source, melamine as the gas source, nano-aluminum hydroxide and attapulgite as fillers, and modified with SiB₆ and expanded graphite. The synthesized IFRE4 sample exhibits excellent flame-retardant properties. In the large plate test, the backside temperature of steel plate coated with IFRE4 was only 158.6 ℃ after 15 min of flame impingement. It achieved a V-0 rating in the vertical burning test, with a limiting oxygen index of 35.7%. In the cone calorimeter test, its peak heat release rate, total heat release, peak smoke production rate, total smoke production, and char residue rate are 271.80 kW/m2, 47.25 MJ/m2, 0.089 m2/s, 16.63 m3, and 39.23%, respectively. This IFRE releases non-combustible gases at high temperatures, forms a dense porous char layer, expands its volume to 8 times the original, and significantly increases thermal resistance between batteries. When used as a fire wall between 10Ah pouch batteries, a 4-mm thick material can stop the TRP, and the maximum temperature of battery is reduced by approximately 50%, reaching only 348 ˚C. This study provides a novel material for suppressing TRP in battery packs in the future, which can effectively enhance battery safety.