Impact-resistant shear stiffening composite foam for safe battery pack

IF 7.8 2区材料科学 Q1 MATERIALS SCIENCE, COMPOSITES

Composite Structures Pub Date : 2026-03-01 Epub Date: 2025-12-13 DOI:10.1016/j.compstruct.2025.119942

Yuxin Xia , Bing Liu , Jianpeng Wu , Zimu Li , Quan Liu , Jianyu Zhou , Xixiang Lv , Sheng Cheng , Xin Liang , Xiang Li , Huaxia Deng , Xinglong Gong

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引用次数: 0

Abstract

Advanced materials are required for lithium-ion battery packs to mitigate impact and fire risks. Unlike conventional foams that offer only passive cushioning with limited energy absorption and flammability, this study develops lightweight composite foam SAE through a hybrid compression foaming process. This material uniquely integrates strain-rate-sensitive hardening properties, V-0 flame retardancy, and thermal stability. The results show that the composite layer with a 5 mm thickness absorbed up to 89 % of maximum impact energy in a drop hammer test, and demonstrated resistance to penetration under anti-impact test by a 0.721 g aluminum ball at an initial velocity of 180 km/h. In battery pack applications, SAE reduces peak impact forces by 20 % and prevents thermal runaway propagation, demonstrating its multifunctional innovative value as a next-generation safety solution for energy equipment.

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抗冲击剪切增强复合泡沫安全电池组

锂离子电池组需要先进的材料来减轻撞击和火灾风险。与传统泡沫只能提供有限能量吸收和可燃性的被动缓冲不同，本研究通过混合压缩发泡工艺开发了轻质复合泡沫SAE。这种材料独特地集成了应变率敏感硬化性能，V-0阻燃性和热稳定性。结果表明：在落锤试验中，厚度为5 mm的复合材料层吸收了89%的最大冲击能；在初始速度为180 km/h的0.721 g铝球抗冲击试验中，复合材料层具有良好的抗侵透性能；在电池组应用中，SAE可将峰值冲击力降低20%，并防止热失控传播，展示了其作为下一代能源设备安全解决方案的多功能创新价值。

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来源期刊

Composite Structures 工程技术-材料科学：复合

CiteScore

12.00

自引率

12.70%

发文量

1246

审稿时长

78 days

期刊介绍： The past few decades have seen outstanding advances in the use of composite materials in structural applications. There can be little doubt that, within engineering circles, composites have revolutionised traditional design concepts and made possible an unparalleled range of new and exciting possibilities as viable materials for construction. Composite Structures, an International Journal, disseminates knowledge between users, manufacturers, designers and researchers involved in structures or structural components manufactured using composite materials. The journal publishes papers which contribute to knowledge in the use of composite materials in engineering structures. Papers deal with design, research and development studies, experimental investigations, theoretical analysis and fabrication techniques relevant to the application of composites in load-bearing components for assemblies, ranging from individual components such as plates and shells to complete composite structures.