Combination of Phase Change Composite Material and Liquid-Cooled Plate Prevents Thermal Runaway Propagation of High-Specific-Energy Battery

Ternary lithium-ion batteries (LIBs) have the advantages of high energy density and high charging efficiency, and they are the preferred energy source for long-life new energy vehicles. However, when thermal runaway (TR) occurs in the ternary LIB, an open flame is easily produced. The burning phenomenon is intense, and the rapid of TR propagation is high; consequently, vehicle-level fire accidents are easily induced. These accidents have become the biggest obstacle restricting the batteries’ development. Therefore, this study investigates the TR behavior of ternary LIBs at the cell and module levels. The addition of an insulation layer alone, including ceramic nano fibers, glass fiber aerogel, and phase-change composite materials, cannot prevent TR propagation. To completely block the TR propagation, we developed a safety prevention strategy, combining the phase-change composite materials with a commercial liquid cooling plate. This approach provides a three-level TR protection mechanism that includes heat absorption, heat conduction, and heat insulation. The use of a 2 mm thick phase change composite material combined with a liquid cooling plate effectively prevents the TR propagation between60 Ah ternary LIBs with 100%SOCs. The front surface temperature of the adjacent cell is maintained near 90 °C, with its maximum temperature consistently stays below 100 °C. This study successfully demonstrates the blockage of TR propagation and offers valuable insights for the thermal safety design of high-specific-energy LIBs; the aim is to improve the overall safety of battery packs in practical applications.