EV Battery Packaging to Prevent Thermal Runaway

Thermal runaway represents a critical factor of catastrophic failure in power battery systems, posing significant safety risks electric vehicle applications. Aluminum alloy casings serve as primary protective barrier, and comprehensive investigation their combustion characteristics is crucial for mitigating potential hazards lithium-ion systems. The present study systematically examines the influence dimensional variations flame-retardant Ni-based surface modifications on mechanisms 5052 aluminum employed configurations. Experimental findings reveal that ignition temperature decreased with oxygen pressure increased. application coating markedly increasing threshold to 1007.8 ± 18.8 K. A robust predictive model characterizing its flame-resistant was developed, demonstrating exceptional statistical validity R2 values consistently exceeding 0.95. Microscopic morphological analysis zones revealed incorporation facilitates formation more oxide film denser solidification zone microstructure.

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A separator for lithium-ion batteries with improved heat resistance, thermal stability, and cycle life compared to conventional separators. The separator comprises a nanocellulose coating on a porous substrate with a surface tension ratio of 0.68 or higher. The nanocellulose can have modified groups like amines, carboxylic acids, sulfonic acids, borates, or phosphates. This enhances heat resistance and bonding strength. An adhesive layer can also be added to prevent coating delamination. The separator enables high energy density, safety, and cycle life in lithium-ion batteries.

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An all-solid-state battery with improved charge/discharge efficiency and lifespan compared to conventional solid-state batteries. The battery uses a coating layer made of a porous network of intertwined fibrous carbon that is coated with an inorganic electrolyte. This coating layer is sandwiched between the anode current collector and the solid electrolyte. The coating provides balanced ionic and electronic conductivity, eliminating the need for a separate anode active material. The coated porous carbon network allows lithium intercalation/deintercalation without internal short circuits, improving cycling stability.

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Energy storage cell design to prevent thermal runaway propagation between cells in high-density batteries like lithium-ion. The cell has an electrode/separator assembly inside a housing with a covering made of porous material between the assembly and housing. The porous covering allows heat transfer between the hotter assembly and cooler housing walls. It prevents insulating layers from trapping heat and stops excessive temperatures in one cell from spreading to others.

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Battery with enhanced high-temperature performance and thermal stability through the synergistic effect of additives in the electrolyte solution. The battery features a positive electrode plate with a single-side active material layer, a negative electrode plate with controlled surface area, and a separator. The electrolyte solution contains a lithium salt, organic solvent, a cyclic silane compound containing unsaturated bonds, and a fluorinated cyclic carbonate compound. The cyclic silane compound enhances the protective film formed on the negative electrode surface, while the fluorinated cyclic carbonate compound prevents electrolyte decomposition. This combination enables the battery to maintain high-temperature performance and thermal stability while achieving enhanced cycling performance compared to conventional lithium-ion batteries.

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A compound with a perfluoroalkyl group, a coating composition containing the compound, a method to make the compound, and an electronic device using the coating composition. The compound has a unique structure with a perfluoroalkyl group, a silane group, and a vinyl group. It can be easily synthesized by reacting a perfluoroalkyl compound with an alkoxy silane compound, followed by elimination to introduce a double bond. This provides a simple and compatible way to introduce a perfluoroalkyl group into compounds for coating applications. The compound and coating composition can have low dielectric properties and enhanced adhesion compared to directly introducing a perfluoroalkyl group into a coating.

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A composite coating agent for ultra-high-nickel single-crystal ternary positive electrode materials that enhances safety and stability through controlled lithium ion migration and electrolyte protection. The coating agent combines a lithium-containing oxide with a lithium-free oxide to create a uniform, leak-resistant layer on the electrode surface. The composition of the coating agent is optimized to balance the necessary lithium ion conductivity with sufficient electrolyte protection and phase stability. This coating agent enables improved lithium ion migration control, reduced electrolyte contact with the electrode surface, and enhanced material durability during charge and discharge cycles.

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Method for forming a positive electrode for lithium-ion batteries that improves stability and cycle life, particularly in high potential and high temperature conditions. The method involves coating a conductive material on the surface of the positive electrode active material, which contains lithium cobalt oxide with added magnesium, fluorine, aluminum, and nickel. The surface concentration of these elements is maximized. Heat treatment at moderate temperatures improves stability. This provides a positive electrode with improved crystal structure stability, reduced cracking, and enhanced cycle life compared to standard lithium cobalt oxide.

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Composite solid electrolyte for batteries that has high ion conductivity, mechanical strength, stability, and cycle life compared to conventional solid electrolytes. The composite electrolyte consists of lithium lanthanum zirconium oxide nanoparticles with a protective layer of lithium phosphate covering the surface. The nanoparticles are dispersed in a fluorine-containing colloid like PVDF. This composite electrolyte improves performance compared to just the nanoparticles alone. The protective layer prevents nanoparticle agglomeration and improves ionic conductivity. The fluorine-containing colloid disperses the nanoparticles and reduces electrical resistance.

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Heat transfer suppression sheet for battery packs that has high strength and holds inorganic particles to improve heat insulation without powder falling. The sheet contains organic fibers with branched structures that entangle and form a 3D skeleton. This provides shape retention and strength when compressed. The branched fibers also adsorb inorganic particles like oxides, aerogels, or balloons to enhance insulation. The sheet can be manufactured using fibers with core-sheath structures where the core melts at a higher temp than the sheath. This allows the sheath to fuse with particles while leaving the core intact.

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Protecting electrical connection components like busbars in battery packs from thermal runaway and fire propagation using aerogel insulation. The insulation encapsulates the busbars to prevent heat, gases, and particulates from adjacent cells during thermal events. The aerogel barrier is sandwiched between the busbar and an optional outer encapsulation layer. This provides insulation between the busbar and cell terminals to contain thermal runaway. It can also be used as a housing around multiple busbars or as an overall pack insulation layer.

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Separator for secondary batteries like lithium-ion batteries that provides improved thermal safety, cycle life, energy density, and rate performance compared to conventional separators. The separator has a coating layer with a three-dimensional skeleton structure filled with secondary particles formed by agglomeration of primary particles. The secondary particles are inorganic particles like dielectric ceramics or electrochemically active materials. Modifying nanocellulose can also be added to the coating layer. This separator design improves heat resistance, bonding strength, electrolyte infiltration, and retention. The secondary particles in the coating layer provide mechanical reinforcement and improved ion transport compared to thin separators. The nanocellulose modification enhances adhesion and thermal stability.

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A method for densifying sulfide-based solid electrolyte materials through the application of an organic coating. The method involves forming a sulfide-based solid electrolyte material with a surface coating containing a hydrophobic thiol compound, followed by densification through cold pressing. The coating protects the electrolyte during pressing while enhancing its mechanical properties and interface conductivity. The resulting densified solid electrolyte pellets can be used in all-solid-state batteries, particularly in secondary cells like lithium-ion batteries, offering improved safety, performance, and energy density compared to conventional liquid-based systems.

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Preparing high-performance negative electrode material for lithium-ion batteries that improves initial discharge capacity, initial efficiency, and cycle life compared to conventional silicon-based materials. The method involves coating a pitch binder on spherical silicon-carbon composite particles. The silicon particles are first mixed with an organic resin and dried to form spherical powders. Then, a pitch solution is applied and the particles are carbonized. This uniformly and densely coats the pitch on the silicon surface, preventing volume expansion and structural destruction during cycling. The pitch-coated silicon-carbon composite has better initial discharge capacity, initial efficiency, and cycle life compared to uncoated silicon composites.

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Lithium-ion battery with enhanced storage characteristics through the incorporation of a protective film at the positive electrode. The battery features a positive electrode with a composite material containing a positive electrode active material and Li3PO4, where the Li3PO4 concentration is optimized at 1-10% of the total material. By achieving a CAE volume fraction of 20% or more, a stable protective film forms at the positive electrode surface, preventing decomposition of the CAE during operation. This film formation enables the battery to maintain its capacity and voltage retention characteristics, particularly at high charge/discharge rates.

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Exterior material for electrical storage devices like batteries that reduces delamination and warpage issues. The material has a layered structure with specific properties in the base layer, adhesive layer, and heat-sealable layer. The base layer is a polyamide film with low heat shrinkage (2.5% or less at 180°C) in the machine direction. The adhesive layer has a glass transition temperature (Tg) of 100-139°C. This combination prevents delamination between the base and barrier layers at high temperatures, and reduces warpage during cutting.

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Battery pack design for electric vehicles that allows high energy density with reduced weight by using a structural battery pack. The pack has prismatic cells with insulative coatings that enable direct cell-to-cell contact and adhesive bonding. This provides mechanical connection while electrically isolating the cells. Cells can also contact structural components through the coatings. The insulation allows cells to act as load-bearing structural elements. This reduces overall pack weight by eliminating separate structural components.

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Battery assembly with metal coated polymer enclosure member that allows lightweight, complex shaped battery cases that can be manufactured without cracking and wrinkling. The battery case has an enclosure made of a metal-coated polymer that provides high rigidity, strength, and fire resistance while allowing complex shapes. The metal coating on the polymer prevents wrinkling and cracking during manufacturing of complex shapes. The metal coating also provides fire resistance to protect the battery.

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A separator for lithium-ion batteries with improved energy density, thermal safety, and capacity retention compared to conventional separators. The separator has a coating on one side of the polyolefin substrate made of nanocellulose and filler. The coating density and thickness are optimized to balance ion conductivity, porosity, and electrolyte retention. The nanocellulose with surface modifications like amino, carboxylic, or phosphoric groups enhances heat resistance. The filler agglomerates provide mechanical support. This coating layer structure enables high energy density separators with good capacity retention, lower shrinkage, and reduced risk of short circuits compared to thin separators or inorganic coatings.

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Positive electrode sheet for lithium-ion batteries with improved safety and low-temperature performance. The sheet has a first safety layer between the current collector and active material in the center region. This layer prevents internal short circuits and extrusion during impacts. The first safety layer has controlled resistance variation in fully charged state (≤15%) to prevent cold temperature issues. Additional layers can be added on the sides for further safety. The uniformity of the first safety layer facilitates manufacturing.

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