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<p>Electric-aircraft lithium-ion batteries, characterized by high-rate charge/discharge and high energy density, impose stringent thermal-safety requirements in confined compartments. However, conventional thermal-management or insulation strategies generally struggle to simultaneously enable efficient heat dissipation during routine operation and thermal runaway propagation (TRP) suppression under abuse conditions. Herein, a carbon aerogel–silica–alumina aerogel sheet–carbon aerogel dual-network aerogel (CA&amp;SAAS) is fabricated through in-situ deposition and integrated supercritical drying and is further coupled with a cold plate (CP) to construct a battery thermal-safety management system (BTSMS). CA&amp;SAAS exhibits a bulk density of 0.275&#xa0;gcm⁻<sup>3</sup> and a specific surface area of 626.37&#xa0;m<sup>2</sup>g<sup>⁻1</sup>. The silica–alumina aerogel sheet (SAAS) core retains thermal conductivity of 0.0652&#xa0;Wm<sup>⁻1</sup>K<sup>⁻1</sup> at 1000&#xa0;°C, while CA&amp;SAAS exhibits a room-temperature thermal conductivity of 0.019&#xa0;Wm<sup>⁻1</sup>K<sup>⁻1</sup>. During four 1C cycles, BTSMS limits <i>T</i><sub>max</sub>/<i>ΔT</i><sub>max</sub> to 34.9/1.8&#xa0;°C, reducing peak temperature and temperature nonuniformity by 46.5% and 56.1%, respectively. A predictive model shows optimized CP parameters constrain <i>T</i><sub>max</sub> to around 45&#xa0;°C at 3C. Thermal runaway tests conducted in the confined space of a full-scale aircraft cargo compartment demonstrate that the BTSMS effectively interrupts TRP in a confined three-cell module, providing a solution for the design of BTSMSs for electric-aircraft battery packs.</p>

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Dual-Network Aerogel-Based Thermal-Safety Management System Design for Electric-Aircraft Battery Packs: Efficient Heat Management and Runaway Protection

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月21日

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  • Jie Yang,
  • Yueyue Xiao,
  • Mingyuan Yan,
  • Xu Huang,
  • Longlong Li,
  • Zhongxin Zhang,
  • Xudong Cheng,
  • Heping Zhang,
  • Yuelei Pan

摘要

Electric-aircraft lithium-ion batteries, characterized by high-rate charge/discharge and high energy density, impose stringent thermal-safety requirements in confined compartments. However, conventional thermal-management or insulation strategies generally struggle to simultaneously enable efficient heat dissipation during routine operation and thermal runaway propagation (TRP) suppression under abuse conditions. Herein, a carbon aerogel–silica–alumina aerogel sheet–carbon aerogel dual-network aerogel (CA&SAAS) is fabricated through in-situ deposition and integrated supercritical drying and is further coupled with a cold plate (CP) to construct a battery thermal-safety management system (BTSMS). CA&SAAS exhibits a bulk density of 0.275 gcm⁻3 and a specific surface area of 626.37 m2g⁻1. The silica–alumina aerogel sheet (SAAS) core retains thermal conductivity of 0.0652 Wm⁻1K⁻1 at 1000 °C, while CA&SAAS exhibits a room-temperature thermal conductivity of 0.019 Wm⁻1K⁻1. During four 1C cycles, BTSMS limits Tmax/ΔTmax to 34.9/1.8 °C, reducing peak temperature and temperature nonuniformity by 46.5% and 56.1%, respectively. A predictive model shows optimized CP parameters constrain Tmax to around 45 °C at 3C. Thermal runaway tests conducted in the confined space of a full-scale aircraft cargo compartment demonstrate that the BTSMS effectively interrupts TRP in a confined three-cell module, providing a solution for the design of BTSMSs for electric-aircraft battery packs.