New Energy

🔥 ​I. Core Properties: Cornerstones of Battery Safety & Efficiency​

  1. ​Flame Retardancy​

Melamine foam’s nitrogen-rich molecular structure (N-content: ​~40%​, up to 70% in optimized processes) releases nitrogen gas when heated, forming a dense char layer for ​self-extinguishing​ without added retardants, meeting:

  • ✅ ​UL 94 V-0​ (US), ✅ ​GB 8624 B1​ (China), ✅ ​EN 13501-1​ (EU);
  • Smoke density (Ds4.0) ​​<50​ (vs. >100 for conventional materials), zero molten droplets/toxic fumes, blocking thermal runaway propagation .
  1. ​Thermal Insulation​
  • ​Ultra-low thermal conductivity (0.022–0.035 W/(m·K))​: ≥99% open-cell 3D network suppresses air convection, impeding heat transfer .
  • ​Broad temperature stability (-180°C to 240°C)​: Long-term tolerance to battery pack environments (80–120°C), short-term peak at 240°C without deformation .
  1. ​Electrical Insulation​
  • ​Permanent insulation: Withstands ​3000V DC, insulation resistance ​100MΩ​ (tested at 1000V), preventing module short circuits .
  • ​Electrochemical corrosion resistance: Resists acids, alkalis, mold, and electrolyte leakage .
  1. ​Lightweight Design​
  • ​Ultra-low density (7–12 kg/m³)​: 1/20 weight of metal/ceramic alternatives, boosting energy density .
  • ​Thin-section applicability (≥0.3mm)​: Flexible sheets adapt to confined spaces with minimal layout disruption .

​Performance Comparison​

​Property​

​Melamine Foam​

​Silicone Foam​

Thermal Conductivity

0.035 W/(m·K)

0.2–0.5 W/(m·K)

Flammability Rating

UL94 V-0

UL94 HB

Density

7–12 kg/m³

40–80 kg/m³

Temperature Range

-180°C~240°C

-50°C~200°C

🔋 ​II. C’s Application Practices​

  1. ​Inter-cell Thermal Barrier Layer​
  • ​Function: Fills cell gaps, absorbs swelling stress during cycling, and blocks heat diffusion during thermal runaway .
  • ​Technical solution: ​0.3–10mm sheets​ (MeFoam、MFYC-6-A0、MFYC-6-A1, series) with >90% compression resilience ensure long-term stability .
  • ​Effect: Delays thermal propagation by ​≥30%​, meeting GB 38031-2020 safety requirements .
  1. ​Liquid Cooling Plate Support Layer​
  • ​Challenge: Thermal pads degrade over time, causing poor contact between cooling plates and batteries .
  • ​Solution: ​1–5mm foam pads​ under cooling plates provide elastic support for consistent thermal interface .
  • ​Engineering advantage: Compression set ​​<5%​​ (vs. >15% for rubber), eliminating collapse risks .
  1. ​Battery Pack Sealing & Vibration Damping​
  • ​Sealing gaskets: Hydrophobic-modified foam (contact angle >120°) replaces silicone, achieving ​IP67/IP68​ protection against moisture .
  • ​Vibration absorption: Custom-cut foam modules between cells and housing absorb mechanical energy, reducing cell damage .

🛠️ ​III. Engineering Innovations: Material-Process Synergy​

  1. ​Composite Reinforcement​
  • ​Ceramic-fiber hybrid: Silica fiber reinforcement boosts temperature resistance to ​1200°C​ (e.g., Sinoyqx YQX-C6 series) .
  • ​Film-backing process: Aluminum foil/flame-retardant nonwoven lamination enhances strength and simplifies installation .
  1. ​Green Manufacturing​
  • ​Zero hazardous additives: Free of halogens, heavy metals, and retardants; incineration calorific value ​23MJ/kg​ for energy recovery .
  • ​Recyclable design: Scrap reuse rate ​>85%​, aligning with C’s “zero-waste factory” goal .