航空锂电池热失控防护与结构轻量化分析

Thermal runaway protection and structural lightweighting of aviation lithium batteries

  • 摘要: 航空锂电池在热失控过程中产生的高温喷射物可能导致电池包顶部结构失效,对机上周围设备、线路和结构的热冲击危害极大. 基于自主搭建的电池热冲击包容性实验平台,研究不同荷电状态(SOC)下锂电池热失控对电池包顶板的高温与冲击影响;比较分析了有机、无机防火涂层在锂电池热失控高温和压力冲击下的被动防护效果,计算预测了涂覆涂层后电池包结构设计的轻量化程度. 结果表明,100%SOC电池发生热失控时,1.0 mm厚度的铝板受冲击后发生穿孔,1.5 mm厚的铝板未发生穿孔实现有效包容;涂覆有机涂层E85S15B3、E80S20和无机涂层APB3后的电池包顶板在电池热冲击下仍保持结构完整性,且板材表面的峰值温度分别下降了93.8%、90.7%和90.0%;1.0 mm厚顶板材料分别涂覆0.5 mm厚有机涂层E85S15B3、E80S20以及无机涂层APB3后,与无涂层3.0 mm厚顶板材料对于高温危害的防护效果相同,重量分别减轻了62.95%、61.63%、62.19%,轻量化效果显著.

     

    Abstract: High-temperature ejecta generated during the thermal runaway process of lithium batteries can compromise the structural integrity of the top plate of the battery pack, posing a severe thermal shock threat to surrounding equipment, wiring, and aircraft structures. This threat is particularly critical in aviation, where ensuring the safety of electrical systems and components is crucial. To investigate the effects of thermal runaway on lithium batteries in a controlled experimental environment, a battery thermal shock containment platform was built. This study evaluates the impact of thermal runaway on the top plate of the battery pack at different states of charge (SOC) and compares the passive protective effects of organic and inorganic fire-resistant coatings under extreme conditions. Furthermore, it explores the potential for weight reduction in the battery pack structure following the application of these coatings. The experimental results reveal a strong correlation between the SOC and the severity of thermal runaway effects. Specifically, higher SOC values increase the risk of catastrophic failure. When a battery at 100% SOC undergoes thermal runaway, a 1.0-mm-thick aluminum plate is punctured upon impact, whereas a 1.5-mm-thick plate remains intact, achieving effective containment. The study demonstrates that applying fire-resistant coatings to the top plate of the battery pack considerably enhances its structural integrity under high-temperature shocks induced by thermal runaway. Organic coatings E85S15B3 and E80S20, along with inorganic coating APB3, reduced the peak surface temperatures of the plates by 93.8%, 90.7%, and 90.0%, respectively. Moreover, this study examines the effect of structural plate thickness on thermal insulation. Increasing the plate thickness from 1.5 to 3.0 mm improves thermal insulation, providing additional protection against high-temperature conditions. The protective effect of a 3.0-mm-thick uncoated top plate was found to be similar to that of a 1.0-mm-thick top plate coated with a 0.5-mm layer, indicating that a thin coating has a comparable performance to that of a thick plate; this makes it applicable in weight-saving designs. Experimental plates coated with E85S15B3 and E80S20 weighed 145.6 and 150.8 g, respectively, reflecting weight reductions of 247.4 and 242.2 g compared with uncoated 3.0-mm-thick plates, corresponding to weight reductions of 62.95% and 61.63%, respectively. The plate coated with APB3 weighed 148.6, 244.4 g lighter than the uncoated 3.0-mm-thick plate, achieving a weight reduction of 62.19%. These results indicate the potential of fire-resistant coatings to enhance the thermal safety and lightweighting of battery pack structures. This study provides valuable theoretical and experimental data to support the development of safer and lighter lithium battery systems for aviation applications. The findings have significant implications for battery pack design, reinforcing the importance of coating technologies in enhancing the safety and performance of aviation lithium battery systems.

     

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