Passive protection containment of high temperature and impact hazards from thermal runaway in aviation power lithium batteries
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摘要: 锂电池热失控造成的热冲击将损坏安装结构，对周围人员和设备安全产生威胁，是限制其航空应用的关键问题。通过自主搭建的锂电池热失控高温冲击实验平台研究发现，单节电池热冲击对电池包顶板的冲击压力高达13.23 kPa，致使其外表面温度高达274 ℃。为了有效包容锂电池热失控造成的高温冲击危害，提出电池包顶板涂敷防火涂层的被动防护方法。通过实验研究表明，环氧树脂基膨胀型防火涂层可通过膨胀有效阻隔锂电池热失控冲击压力影响，通过吸收热量降低并延缓电池包顶板的温度上升。分析锂电池热失控包容性验证实验结果可知，1.0 mm厚的E80S20涂层和E85S15B3涂层分别使电池包顶板最高温度下降52.16%和55.80%，结构最高形变分别降低72.2%和44.4%。研究表明防火涂层被动防护技术能够有效提升电池舱体对热失控高温和冲击危害的包容性，可作为航空动力锂电池系统安全性设计的有效措施。Abstract: The thermal shock caused by thermal runaway of lithium batteries will damage the installation structure and pose a threat to the safety of surrounding personnel and equipment, which is a key issue limiting their aviation applications. Through a self-built high-temperature impact experimental platform for lithium battery thermal runaway, it was found that the impact pressure on the battery pack top plate from single-cell thermal shock can reach up to 13.23 kPa, causing the external surface temperature to exceed 274 ℃. The combined effect of high temperature and impact pressure increases the risk of the casing undergoing plastic deformation, buckling, or even failure. To effectively mitigate such risks, a passive protection method of coating the top plate of the battery pack with fireproof coating is proposed. Through large panel combustion experiments and cone calorimeter tests, it was found that the epoxy resin-based intumescent fireproof coatings can effectively block the impact pressure of lithium battery thermal runaway by expanding, and they absorb heat, reducing and delaying the temperature rise of the battery pack top plate, demonstrating excellent thermal shock resistance. By comparing the containment effects of fireproof coatings of different thicknesses, it was found that the 1mm coating is more suitable for practical application needs. Referring to relevant airworthiness regulations, verification tests were conducted on the containment of lithium battery thermal runaway. The analysis of the experiment results shows that the 1.0 mm thick E80S20 coating and E85S15B3 coating reduced the maximum temperature of the battery pack top plate by 52.16% and 55.80%, respectively. Additionally, the maximum structural deformation decreased by 72.2% and 44.4%, respectively. The study indicates that passive protection technology of fireproof coating can effectively enhance the containment of high temperatures and impact hazards caused by thermal runaway. This approach can serve as an effective measure in the safety design of aviation power lithium battery systems.
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图 2 不同SOC电池热失控下铝板背火面温度和所受冲击压力
Figure 2. Temperature and impact pressure on the backside of aluminum plates under thermal runaway of different SOC batteries
图 3 丁烷火焰冲击下涂层背火面的温度变化曲线
Figure 3. Temperature change curves of coating backfired surfaces under butane flame impact
图 4 涂层受热后的膨胀高度与形貌特征
Figure 4. Expansion height and morphological characteristics of coatings after heating
图 5 涂层厚度对铝板背火面最高温度与所受最大冲击压力的影响
Figure 5. Influences of coating thicknesses on the maximum temperature and maximum impact pressure on the backside of aluminum plates
图 6 热失控包容性实验平台示意图
Figure 6. Schematic diagram of the thermal shock containment testing platform
图 7 不同涂层在电池热失控高温冲击下的表面残留物
Figure 7. Surface residues of different coatings under thermal runaway and high temperature impact of batteries
图 8 铝板达到峰值温度瞬间的热像图
Figure 8. Thermal images at the moment when aluminum plates reach their peak temperature
图 9 铝板达到峰值温度时瞬态热分布
Figure 9. Transient thermal distribution of aluminum plates at peak temperature
图 10 铝板外表面的最高温度变化曲线
Figure 10. The maximum temperature change curve of the outer surface of the aluminum plates
图 11 铝板在电池热失控冲击后的形变情况
Figure 11. Deformation of aluminum plates after thermal runaway impact of batteries
表 1 涂料中不同组分的质量分数
Table 1. Mass fractions of different components in coatings %
涂料 环氧树脂 坡缕石+海泡石 有机硅树脂 APP+MEL+PER 593固化剂 碳化硼 E80S20 50.79 4.76 12.70 19.05 12.70 0.00 E85S15B3 52.95 2.34 9.35 18.69 12.46 4.21 
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表 2 不同涂层的锥形量热测试参数
Table 2. Cone calorimeter test parameters for different coatings
样品 TTI/s PHRR/(kW·m−2) THR/(MJ·m−2) MRR/% E80S20 31 181.34 39.31 56.88 E85S15B3 29 170.53 35.62 58.32
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表 3 不同厚度涂层的包容效果
Table 3. Containment effects of coatingswith different thicknesses
涂层材料 厚度/mm Tmax/℃ CT/% pmax/kPa Cp/% E80S20 0.5 144.95 47.1 10.21 22.8 1.0 106.31 61.2 9.61 27.3 2.0 100.28 63.4 9.21 30.4 E85S15B3 0.5 95.08 65.3 10.92 17.6 1.0 89.32 67.4 10.5 20.5 2.0 85.49 68.8 10.25 22.6
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