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<p>Achieving high safety in energy storage systems is paramount but hindered by the catastrophic risks of thermal runaway propagation (TRP). This study develops a gradient-laminated ceramifiable silicone foam composite to resolve the inherent trade-off between thermal insulation and dynamic impact toughness. By integrating a polydimethylsiloxane foam matrix with a load-bearing glass fiber fabric skeleton, the material utilizes silane coupling agents for robust interfacial adhesion, while multiscale fillers promote synergistic ceramicization. Characterization reveals robust mechanical durability, maintaining stable elasticity across a wide temperature range (− 40 to 300&#xa0;°C) and retaining 93% residual stress after 1,000 compression cycles. Under extreme thermal exposure, the foam transforms into a dense ceramic barrier, reducing total heat release by 54.4% and sustaining thermal protection for over 30&#xa0;min. Crucially, during battery module testing, this architecture efficiently intercepts high-velocity gas jets and confines thermal runaway to a single cell. Fabricated via a scalable process, this composite paves a viable way for constructing intrinsically safe energy storage systems. </p>

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Constructing Intrinsically Safe Lithium-Ion Battery Energy Storage via Gradient-Laminated Ceramifiable Silicone Foams

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年5月24日

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  • Shuilai Qiu,
  • Jingyao Xu,
  • Congling Shi,
  • Laibin Zhang

摘要

Achieving high safety in energy storage systems is paramount but hindered by the catastrophic risks of thermal runaway propagation (TRP). This study develops a gradient-laminated ceramifiable silicone foam composite to resolve the inherent trade-off between thermal insulation and dynamic impact toughness. By integrating a polydimethylsiloxane foam matrix with a load-bearing glass fiber fabric skeleton, the material utilizes silane coupling agents for robust interfacial adhesion, while multiscale fillers promote synergistic ceramicization. Characterization reveals robust mechanical durability, maintaining stable elasticity across a wide temperature range (− 40 to 300 °C) and retaining 93% residual stress after 1,000 compression cycles. Under extreme thermal exposure, the foam transforms into a dense ceramic barrier, reducing total heat release by 54.4% and sustaining thermal protection for over 30 min. Crucially, during battery module testing, this architecture efficiently intercepts high-velocity gas jets and confines thermal runaway to a single cell. Fabricated via a scalable process, this composite paves a viable way for constructing intrinsically safe energy storage systems.