Abstract

The issue of thermal runaway in power batteries of new-energy vehicles occurs frequently, posing a serious threat to life and property safety. This study aims to develop a high-performance fire-proof coating to address this problem. Specifically, the research focused on constructing an organic-inorganic composite intumescent fire-resistant coating, with modified halloysites (Ti-HNTs) serving as the key component. In this coating system, the intumescent flame-retardant (IFR) system and Ti-HNTs were employed as the organic and inorganic components, respectively, while water-based epoxy resin emulsion was selected as the matrix material. Through the utilization of XPS, FTIR, and SEM techniques, it was verified that the Ti-HNTs were successfully modified and integrated well with the coating matrix. Following further optimization of the Ti-HNTs proportion and coating thickness, it was determined that the coating containing 4% Ti-HNTs with a designed thickness of 1.5 mm exhibited the optimal fire-proofing performance. In the fire-resistance experiment, after 10 min of testing, the temperature of this coating could reach a minimum of 215.9 °C. Compared to the control group, its heat-insulation effect was enhanced by 49.4%, with an expansion multiplier of 37.7 and a maximum smoke density of 22.55. These results were significantly superior to those of the control group without the addition of Ti-HNTs. SEM analysis indicated that the coating could form a uniform and dense carbon layer, with an inner surface featuring a honeycomb-bubble structure. This SEM-analyzed Ti-HNTs-modified fire-proof coating demonstrated excellent fire resistance and thermal-isolation effects in new-energy vehicle batteries, thus providing reliable fire protection for the batteries. Additionally, impact-resistance tests revealed that the coating could withstand a simulated battery pressure-relief impact without penetration, maintaining its structural integrity and thermal-barrier function. This further validated its reliability for battery fire protection.

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