Aerogel Thermal Insulation for EV Battery Safety

Aerogel composite with improved thermal insulation properties that can maintain constant thermal insulation even when exposed to pressurization environments. The composite has a structure with aerogel particles dispersed on a fiber substrate and in the voids between fibers. The aerogel has a specific small angle X-ray scattering (SAXS) profile with slope between -2.80 and -2.20 in a wave number range of 0.015/Å to 0.035/Å. This composite provides thermal insulation without significant degradation even under pressure compared to regular aerogels.

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Aerogel composite with enhanced thermal performance that maintains its insulation properties even under pressure. The composite comprises a three-dimensional network structure of aerogel particles with pore sizes of 2 nm to 20 nm, combined with a silica-based aerogel matrix. When subjected to pressure in a direction perpendicular to the cross-section, the aerogel maintains its thermal resistance characteristics, with compression recovery rates exceeding 90%. This demonstrates the aerogel's ability to maintain its thermal insulation properties even under pressure, making it suitable for applications requiring consistent thermal performance.

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Aerogel composite that maintains its heat insulation properties even under pressure conditions. The composite consists of a three-dimensional network structure formed by agglomerating or combining aerogel particles with sizes ranging from 2 nm to 20 nm. When subjected to horizontal pressure, the composite exhibits a heat transmission coefficient of less than 1.8 times its pre-pressurization value, maintaining its thermal insulation performance. This compression recovery characteristic ensures the composite retains its insulation properties even when subjected to external pressure, making it suitable for applications requiring high-temperature insulation without compromising thermal performance.

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A heat insulating element for battery packs that enhances thermal management through improved aerogel-based insulation. The element comprises a core layer of aerogel with controlled water absorption, encapsulated by two layers of hydrophobic encapsulation films. The encapsulation films are applied on both sides of the aerogel core, with the encapsulation films having a water absorption rate between 0.5% and 10%. This dual-layer design provides enhanced thermal performance by maintaining the aerogel's structural integrity while preventing moisture absorption, thereby maintaining the aerogel's insulating properties.

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Composite membrane for secondary batteries that enhances thermal stability through improved airgel dispersion and mechanical properties. The membrane comprises a polymer matrix and airgel particles with hydrocarbon side chains, where the airgel particles undergo controlled modification to enhance their thermal conductivity while maintaining mechanical integrity. The airgel particles are dispersed in the polymer matrix through optimized mixing and extrusion processes, resulting in a composite membrane with enhanced thermal insulation properties.

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Preparation of thermal insulation cotton for power batteries that improves the rebound rate through a novel approach. The cotton is produced by creating silica aerogels through tetraethoxysilane gelation, aging, and drying, followed by a specialized polyurethane-based foam layer. The foam layer is then applied to the aerogel matrix, where sodium bicarbonate reacts with the sponge to create open pores. This creates a unique porous structure that enhances thermal insulation properties by maximizing gas exchange. The aerogel matrix serves as a thermal buffer while the foam layer provides additional structural support. The resulting insulation cotton combines the benefits of aerogel and foam technologies to improve battery performance.

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Aerogel-based thermal management materials for battery cells and modules that achieve high thermal resistance while maintaining structural integrity. The materials incorporate aerogel structures with controlled pore sizes and surface areas, combined with innovative extraction techniques that prevent pore collapse during liquid extraction. The aerogel framework provides excellent thermal conductivity, while the extraction method ensures minimal structural damage during the extraction process. The resulting materials enable efficient thermal management of battery cells while maintaining their structural integrity.

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Aerogel-based thermal management components for electric vehicles that achieve high thermal resistance while minimizing material thickness and weight. The components utilize aerogel materials with low density, open-cell structures and large pore volume, which enable exceptional thermal insulation properties. The aerogel components are combined with compliant aerogel layers and thermal management materials to create multi-layered thermal barrier systems. These systems provide effective thermal protection while maintaining structural integrity, making them suitable for battery cells, battery assemblies, and other thermal management applications in electric vehicles.

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A thermal battery with integrated aerogel insulation that achieves both thermal insulation and structural support. The battery has an aerogel insulation layer sandwiched between its outer and inner shells, with an additional aerogel block positioned between the inner and outer shells. This integrated design eliminates the need for separate insulation elements while maintaining structural integrity. The aerogel blocks are arranged between the outer and inner shell walls, creating a single, continuous insulation system that provides excellent thermal performance while minimizing space requirements.

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Lithium-ion battery pack device for high-temperature applications, particularly for aerospace and extreme vibration environments. The device features a specially designed frame comprising a glass cloth board with polished flat surfaces, a cylindrical battery module encapsulated within, and integrated bus bars and cable routing channels. The device incorporates a thermal management system comprising an aerogel thermal interface layer and a reflective polyimide film outer surface, which together enhance temperature regulation and radiation resistance. The device achieves high performance under extreme vibration conditions, including operating temperatures up to 80°C and vibration amplitudes of 10.8g, while maintaining a minimum energy capacity of 15 kWh.

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Aerogel thermal insulation sheet for lithium-ion battery applications that enhances safety and durability through a novel aerogel material composition. The sheet incorporates a specially developed aerogel matrix that incorporates a unique combination of aerogel powders and additives, which prevents powder erosion and maintains structural integrity during thermal expansion. This composition enables the sheet to maintain its thermal insulation properties while ensuring the safety of lithium-ion batteries during thermal stress.

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A method for preparing MXene-based aerogel materials through a novel template-assisted approach that enables the formation of three-dimensional aerogel structures with superior electrochemical properties. The method involves sonicating MXene dispersion in deionized water, followed by phase separation and self-assembly with functionalized nanocellulose crystals. The resulting aerogel exhibits enhanced mechanical stability and electrochemical performance compared to conventional aerogel materials, particularly when incorporating MXene at high concentrations. The aerogel structure is further stabilized through cross-linking reactions with polyurethane, resulting in a durable and porous material suitable for electrochemical applications.

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Aerogel heat-insulating heat sink for battery packs of new energy vehicles that provides improved thermal management for battery packs in electric vehicles. The heat sink has a first insulating layer made of aerogel sandwiched between a second insulating layer of aerogel felt and a conductive layer of copper foil and graphene film. This sandwich structure isolates heat laterally between battery packs while allowing it to conductively dissipate through the bottom. The aerogel insulation provides high thermal resistance and flexibility to accommodate pack expansion.

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Thermal insulation composition for lithium-ion battery modules that combines aerogel-based thermal management with organic resin-based matrix. The composition comprises aerogel material with controlled pore size, where the aerogel is prepared through controlled aging and supercritical drying. The aerogel is then infiltrated with an organic resin under vacuum, followed by curing under pressure. This composite material provides superior thermal insulation properties compared to traditional aerogel-based solutions, with enhanced thermal conductivity and mechanical strength.

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Heat-insulating and fire-resistant material for batteries that provides good thermal insulation and fire protection without adding significant weight or thickness to the battery. The material contains a thin insulating layer made of porous material with hollow particles attached. The insulating layer has a low bulk density (0.05-0.30 g/cm3) and particle size (30-1000 μm) to maximize porosity and hollow particle filling. This allows the insulation layer to be thin yet effective at blocking heat transfer and preventing thermal runaway propagation between battery cells.

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Thermal insulation sandwich layer with improved performance through a unique honeycomb core structure. The sandwich consists of a honeycomb core with alternating rubber and aerogel layers, where the core is filled through a process of alternating core filling with these materials. The outermost layers are rubber. This design provides exceptional thermal insulation properties while maintaining structural integrity, with the aerogel layers enhancing thermal performance and the rubber layers providing durability.

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Lithium battery packaging material that simultaneously provides both thermal and cryogenic protection. The material comprises a substrate, a thermal management layer comprising aerogel, a reinforcement layer containing heat dissipation material, and a cryogenic protection layer comprising polyester nanocomposite coating. These layers are sequentially stacked on the substrate surface. The material demonstrates excellent thermal performance at elevated temperatures while maintaining high cryogenic stability below -40°C.

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Honeycomb substrate-reinforced aerogel composite material and preparation method, comprising a honeycomb material with pores that penetrate both above and below the aerogel matrix, and an aerogel matrix within the honeycomb structure. The honeycomb structure is created through infiltration of the aerogel matrix into the honeycomb pores, followed by aging and drying to form a solid honeycomb. This composite material exhibits superior thermal insulation properties compared to conventional aerogel composites, with enhanced mechanical strength and durability.

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Aerogel composite with enhanced thermal insulation properties through a novel reinforcement strategy. The composite consists of a base aerogel layer with integrated reinforcing material and aerogel skeleton, where the reinforcing material is strategically integrated into both the base aerogel and the aerogel skeleton. The base layer serves as the primary aerogel component, while the integrated reinforcing material enhances its thermal insulation performance. The aerogel skeleton provides structural integrity, while the integrated material ensures continuous reinforcement throughout the aerogel structure. This integrated reinforcement approach enables the aerogel to maintain its aerogel structure while achieving improved thermal insulation properties.

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A waterborne polyurethane composite aerogel with enhanced thermal insulation properties through the integration of nanoparticle-based heavy network structures. The aerogel comprises a two-dimensional nanoparticle network, chemically cross-linked polyurethane network, and phase-separated aqueous polyurethane network. This composite aerogel exhibits superior thermal insulation performance while maintaining low thermal conductivity, high temperature resistance, and excellent hydrophobicity.

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