Fillers for the transportation of defective batteries

Fillers for the transportation of defective lithium-ion batteries at a glance

The transportation of defective lithium-ion batteries poses a considerable challenge. Lithium-ion batteries are widely used in many electronic devices and offer a high energy density at a comparatively low weight. However, defective batteries pose a high risk of overheating, short circuits or even fires. These risks are exacerbated by mechanical damage, faulty electronics or incorrect storage.

In addition, strict regulations apply to the transportation of these batteries, particularly with regard to the international transport of hazardous goods. To minimize the risk, it is necessary to take special precautions that go beyond simple packaging solutions.

Why are special fillers necessary for transportation?

Lithium-ion batteries can get into a thermal runaway in the event of defects or mechanical damage, which leads to intense heat development and can potentially cause fires. Simple packaging materials such as cardboard or plastic do not offer sufficient protection in such cases. This is where special fillers come into play, which have been developed to ensure safety during transportation.

The task of these fillers is to insulate the batteries, absorb potential heat development and prevent flames from breaking out. Without these special fillers, the transportation of defective lithium-ion batteries would be practically impossible.

What fillers are available?

There are various fillers that have been specially developed for the transportation of lithium-ion batteries. These can be roughly divided into two categories: inert fillers and active cooling fillers.

Inert fillers

Inert fillers are primarily used for physical insulation and to protect the environment from potential hazards. They do not conduct heat and help to absorb mechanical shocks.

Vermiculite

Vermiculite is a mineral that expands when heated and is therefore particularly suitable for insulation. It is often used as a loose filling material and offers very good heat and shock absorption.

Advantages of vermiculite:

• Very heat-resistant
• Good shock absorption
• Inexpensive

Disadvantages of vermiculite:

• Relatively heavy
• No active cooling

Perlite

Similar to vermiculite, perlite is a porous, mineral material that also provides good insulation. It is often used for the transportation of hazardous goods as it is flammable and can withstand high temperatures.

Advantages of perlite

• Low weight
• High temperature resistance

Disadvantages of perlite

• Lower mechanical damping compared to other fillers

Actively cooling fillers

Active cooling fillers go one step further by not only insulating, but also actively absorbing the heat generated by a faulty battery. They can lower the temperature of the battery and thus reduce the risk of thermal runaway.

Pyrobubbles

Pyrobubbles are small, hollow glass spheres that have a high temperature resistance and can effectively absorb thermal energy. They have excellent insulating properties and are non-flammable, making them an ideal filler for transporting defective batteries.

Advantages of Pyrobubbles

• Extremely heat-resistant
• Low weight
• Environmentally friendly

Disadvantages of pyrobubbles

• Higher costs than inert fillers

Special gels and mats

In some cases, special gels or mats are also used that have the ability to absorb heat and actively cool the battery. However, these materials are often more expensive and more complex to handle.

Advantages of gels and mats

• Active cooling
• High level of protection in extreme conditions

Disadvantages of gels and mats

• High costs
• Complex application

Advantages and disadvantages of fillers

While inert fillers such as vermiculite and perlite are primarily characterized by their cost efficiency and easy handling, they do not offer active protection against thermal hazards. They merely insulate and reduce the effects of mechanical shocks. Actively cooling fillers such as pyrobubbles or special gels are more expensive, but offer much greater protection due to their ability to actively absorb heat and thus significantly reduce the risk of fire.