Large-scale assembly of isotropic nanofiber aerogels based on columnar-equiaxed crystal transition.

Ice-templating technology holds great potential to construct industrial porous materials from nanometers to the macroscopic scale for tailoring thermal, electronic, or acoustic transport. Herein, we describe a general ice-templating technology through freezing the material on a rotating cryogenic drum surface, crushing it, and then re-casting the nanofiber slurry. Through decoupling the ice nucleation and growth processes, we achieved the columnar-equiaxed crystal transition in the freezing procedure. The highly random stacking and integrating of equiaxed ice crystals can organize nanofibers into thousands of repeating microscale units with a tortuous channel topology. Owing to the spatially well-defined isotropic structure, the obtained Al2O3·SiO2 nanofiber aerogels exhibit ultralow thermal conductivity, superelasticity, good damage tolerance, and fatigue resistance. These features, together with their natural stability up to 1200 °C, make them highly robust for thermal insulation under extreme thermomechanical environments. Cascading thermal runaway propagation in a high-capacity lithium-ion battery module consisting of LiNi0.8Co0.1Mn0.1O2 cathode, with ultrahigh thermal shock power of 215 kW, can be completely prevented by a thin nanofiber aerogel layer. These findings not only establish a general production route for nanomaterial assemblies that is conventionally challenging, but also demonstrate a high-energy-density battery module configuration with a high safety standard that is critical for practical applications.

Thermal-Switchable, Trifunctional Ceramic-Hydrogel Nanocomposites Enable Full-Lifecycle Security in Practical Battery Systems.

Thermal runaway (TR) failures of large-format lithium-ion battery systems related to fires and explosions have become a growing concern. Here, we design a smart ceramic-hydrogel nanocomposite that provides integrated thermal management, cooling, and fire insulation functionalities and enables full-lifecycle security. The glass-ceramic nanobelt sponges exhibit high mechanical flexibility with 80% reversible compressibility and high fatigue resistance, which can firmly couple with the polymer-nanoparticle hydrogels and form thermal-switchable nanocomposites. In the operating mode, the high enthalpy of the nanocomposites enables efficient thermal management, thereby preventing local temperature spikes and overheating under extremely fast charging conditions. In the case of mechanical or thermal abuse, the stored water can be immediately released, leaving behind a highly flexible ceramic matrix with low thermal conductivity (42 mW m-1 K-1 at 200 °C) and high-temperature resistance (up to 1300 °C), thus effectively cooling the TR battery and alleviating the devastating TR propagation. The versatility, self-adaptivity, environmental friendliness, and manufacturing scalability make this material highly attractive for practical safety assurance applications.

A comparative analysis on thermal runaway behavior of Li (NixCoyMnz) O2 battery with different nickel contents at cell and module level.

The problem of thermal runaway (TR) propagation challenges the safety design of battery packs, because it aggravates the thermal hazards to accidents. There are many unsolved scientific questions in understanding the mechanisms of TR and its propagation behavior for large format lithium-ion batteries (LIBs). LiNixCoyMnzO2(NCM) is considered as one of the most promising cathode materials for lithium-ion batteries LIBs, given its higher energy design and lower cost. However, higher Nickel (Ni) content of cathode material worsens the thermal stability of LIBs. This paper provides a comparative analysis on the TR propagation behavior of NCM battery with different Ni ratios. Results have shown that when the characteristic temperatures of TR {T1, T2, T3}and the specific electrochemical energy of the cell are similar, TR propagation behavior will be similar, no matter what kinds of chemistry the cell has. Observation suggests that the average propagation time within a large format cell is 7-10 s in module tests. Besides, the internal temperature of the cell has an order of NCM622 ≥ NCM523 ≥ NCM111,whereas the mass is ordered by NCM622 > NCM523 > NCM111.This work firstly reports the TR feature in large format LIBs with different Ni ratios, both at cell and module level, providing the guidelines for engineering practice and further theoretical researches.