Enhancing Thermal Protection in Lithium Batteries with Power Bank-Inspired Multi-Network Aerogel and Thermally Induced Flexible Composite Phase Change Material

Abstract Thermal runaway (TR) is considered a significant safety hazard for lithium batteries, and thermal protection materials are crucial in mitigating this risk. However, current thermal protection materials generally suffer from poor mechanical properties, flammability, leakage, and rigid crystallization, and they struggle to continuously block excess heat transfer and propagation once thermal saturation occurs. This study proposes a novel type of thermal protection material: an aerogel coupled composite phase change material (CPCM). The composite material consists of gelatin/sodium alginate (Ge/SA) composite biomass aerogel as an insulating component and a thermally induced flexible CPCM made from thermoplastic polyester elastomer as a heat-absorbing component. Inspired by power bank, we coupled the aerogel with CPCM through the binder, so that CPCM can continue to ‘charge and store energy’ for the aerogel, effectively absorbing heat, delaying the heat saturation phenomenon, and maximizing the duration of thermal insulation. The results demonstrate that the Ge/SA aerogel exhibits excellent thermal insulation (with a temperature difference of approximately 120 °C across a 1 cm thickness) and flame retardancy (achieving a V-0 flame retardant rating). The CPCM exhibits high heat storage density (811.9 J g −1 ), good thermally induced flexibility (bendable above 40 °C), and thermal stability. Furthermore, the Ge/SA-CPCM coupled composite material shows even more outstanding thermal insulation performance, with the top surface temperature remaining at 89 °C after 100 min of exposure to a high temperature of 230 °C. This study provides a new direction for the development of TR protection materials for lithium batteries.