This article overviews the causes of lithium-ion battery fires, examines the associated risks, and discusses preventive measures and industry contributions toward improving lithium battery safety. Contact online >>
This article overviews the causes of lithium-ion battery fires, examines the associated risks, and discusses preventive measures and industry contributions toward improving lithium battery safety.
Lithium-ion batteries (LIBs) are integral to modern technology, powering consumer electronics, electric vehicles (EVs), and renewable energy systems due to their high energy density, low self-discharge, rapid charging, and long lifespan. However, due to the volatility of their internal components, LIBs also present safety risks, notably the potential for fires and explosions.
Even though the reported incidents of LIB fires are low—ranging from one in one million to one in ten million units—understanding the causes of these incidents is crucial for improving battery safety in consumer and industrial applications.1
This happens when the battery's internal temperature exceeds 90-120 °C, triggering exothermic reactions in the electrolyte that decompose the solid electrolyte interface (SEI) and other components, releasing more heat.
Internal short circuits, caused by manufacturing defects, physical damage, or improper handling, can cause the separator to collapse and allow direct contact between the anode and cathode. This contact generates localized heating, triggering a thermal reaction and igniting the flammable electrolyte.
Overcharging a LIB beyond its voltage limit causes excess lithium ions to accumulate on the anode, forming metallic lithium. This can lead to dendrites—needle-like structures that may pierce the separator and cause internal short circuits.
Additionally, prolonged exposure to high temperatures accelerates material degradation, increasing fire risk; even ambient temperatures above 40 °C can harm battery health, while extreme temperatures may lead to rapid failure and combustion.
External physical damage, such as impact, puncture, or bending, can compromise battery safety by deforming the casing and exposing internal components. This can lead to electrolyte exposure to oxygen, resulting in increased fire risk.2,3
Modern LIBs have protective devices like safety vents, current interrupt devices (CID), and positive temperature coefficient (PTC) elements that help prevent thermal runaway by releasing pressure, interrupting current flow during overheating, and increasing resistance to limit heat generation.
The International Electrotechnical Commission (IEC) 62133 and UL 1642 are prominent standards that enforce testing protocols to prevent overcharging, short-circuiting, and overheating. They also mandate proper labeling and safety features for batteries used in consumer electronics and electric vehicles.
Additionally, countries and regions, such as the United States and the European Union, have established further testing and certification requirements, such as RoHS directives and UL certifications, for commercial use and transportation of LIBs.5-7
Adhering to manufacturer guidelines is essential for preventing LIB fires. Key practices include charging within the recommended voltage range, properly disposing of damaged batteries, and keeping charge levels below 50 % during moderate temperature storage to minimize fire risks.8
Thermo Shield™ is a lightweight fire-suppressant paper that cools package interiors and withstands temperatures over 1,500 degrees Fahrenheit, while the TR Sleeve™ prevents thermal runaway in battery cells. Both products have passed rigorous testing and comply with proposed safety standards for LIB transport.
PACT recently partnered with BS Technics to introduce these innovations in the Korean market, supporting major brands such as Samsung and Hyundai with a focus on sustainability and safety in the electric vehicle sector.9
Jensen Hughes provides performance-based life safety consulting and risk assessment for LIB applications. The company specializes in custom fire protection systems tailored to address the unique threats posed by these batteries, including explosion control measures and gas detection systems. In addition, its control strategies, such as deflagration venting, are very effective in mitigating thermal runaway.10
The initiative focuses on early detection of battery failures and rapid intervention to prevent fires, demonstrating that timely activation can stabilize the battery before escalation. It has garnered significant interest from global manufacturers and end-users.11
FirePro's condensed aerosol fire suppression technology is another effective solution for mitigating the fire risks of LIBs. This system works by interrupting the chemical reactions in flames, activating a rapidly expanding agent composed of potassium carbonate, which neutralizes harmful byproducts from battery fires, prevents the generation of flammable gases, and facilitates temperature reduction below critical levels for thermal runaway.
FirePro systems are deployed globally, including at the Princess Elisabeth Antarctica research project and Samsung SDI in Korea, providing effective fire suppression for large-scale LIB systems while adhering to operational and environmental requirements.12
Ongoing research continues to address the safety challenges posed by LIBs. For instance, Swansea University researchers recently developed a method for producing large-scale, defect-free graphene current collectors that enhance lithium battery safety.
These foils have an exceptional thermal conductivity of up to 1,400.8 W m⁻¹ K⁻¹, nearly ten times higher than traditional materials like aluminum and copper. This addresses thermal runaway risks in LIBs, particularly for electric vehicles.
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