Continuous rapid fabrication of fluffy ceramic sponge with high thermomechanical properties for battery pack runaway protection

Abstract The large-scale application of power batteries has brought a huge demand for lightweight fireproof and heat insulation aerogels. However, the discontinuous processing techniques for aerogels increase synthesis costs and inhibit large-scale manufacture. Here, we propose a self-templated curl-stacking electrospinning method to directly synthesize mechanically resilient fluffy ceramic fiber sponges (FCFSs) without using polymer templates, which simultaneously have amazing thermal-mechanical and thermal insulation properties under extreme conditions. The FCFSs have a low mass density (5.49 mg/cm3). This small thermal conductivity is 0.026 W/m·K, and has a high compression stability, and therefore has good potential in battery packs’ thermal runaway protection.