Constructing Intrinsically Safe Lithium-Ion Battery Energy Storage via Gradient-Laminated Ceramifiable Silicone Foams

Achieving high safety in energy storage systems is paramount but hindered by the catastrophic risks of thermal runaway propagation (TRP). This study develops a gradient-laminated ceramifiable silicone foam composite to resolve the inherent trade-off between thermal insulation and dynamic impact toughness. By integrating a polydimethylsiloxane foam matrix with a load-bearing glass fiber fabric skeleton, the material utilizes silane coupling agents for robust interfacial adhesion, while multiscale fillers promote synergistic ceramicization. Characterization reveals robust mechanical durability, maintaining stable elasticity across a wide temperature range (- 40 to 300 °C) and retaining 93% residual stress after 1,000 compression cycles. Under extreme thermal exposure, the foam transforms into a dense ceramic barrier, reducing total heat release by 54.4% and sustaining thermal protection for over 30 min. Crucially, during battery module testing, this architecture efficiently intercepts high-velocity gas jets and confines thermal runaway to a single cell. Fabricated via a scalable process, this composite paves a viable way for constructing intrinsically safe energy storage systems.