Influence of cathode materials on thermal characteristics of lithium-ion batteries

In this work, the thermal stability of four types of 18,650 lithium-ion batteries with LiCoO2 (LCO), LiFePO4 (LFP), LiNi0.8Co0.1Mn0.1O2 (NCM811) and LiNi0.8Co0.15Al0.05O2 (NCA) materials as cathodes are experimentally investigated by the accelerating rate calorimeter (ARC) and the isothermal battery testing calorimeter (iso-BTC) under adiabatic and isothermal conditions, respectively. The thermal runaway danger level of these batteries can be ranked as LCO > NCA > NCM811 >> LFP by judging from the values of Tmax and HRmax, nominal. The higher the nickel and cobalt content, the higher the lithium-ion battery capacity, but the worse the thermal stability. The Qtotal of NCA is the largest in the complete standard charge and discharge process, due to that the capacity of NCA is significantly higher than that of the other three batteries, resulting in remarkable increase in Qirre proportioned to the square of the current. When the ambient temperature rises, the energy release decreases owing to the decrease in the internal resistance of the battery. These studies are expected to have important implications for the subsequent safe design of commercial lithium-ion batteries with different cathode materials.

Nonflammable Polyfluorides-Anchored Quasi-Solid Electrolytes for Ultra-Safe Anode-Free Lithium Pouch Cells without Thermal Runaway

The safe operation of rechargeable batteries is crucial because of numerous instances of fire and explosion mishaps. However, battery chemistry involving metallic lithium (Li) as the anode is prone to thermal runaway in flammable organic electrolytes under abusive conditions. Herein, an in situ encapsulation strategy is proposed to construct nonflammable quasi-solid electrolytes through the radical polymerization of a hexafluorobutyl acrylate (HFBA) monomer and a pentaerythritol tetraacrylate (PETEA) crosslinker. The quasi-solid system eliminates the inherent flammability of ether electrolytes with zero self-extinguishing time owing to the gas-phase radical capturing ability of HFBA. Additionally, the graphitized carbon layer generated during the decomposition of PETEA at high temperatures obstructs the heat and oxygen required for combustion. When coupled with Au-modified reduced graphene oxide anodic current collectors and lithium sulfide cathodes, the assembled anode-free Li-metal cell based on the quasi-solid electrolyte exhibits no signs of cell expansion or gas generation during cycling, and thermal runaway is eliminated under multiple mechanical, electrical, and thermal abuse scenarios and even rigorous strikes. This nonflammable quasi-solid configuration with gas- and condensed-phase flame-retardant mechanisms can drive a technological leap in anode-free Li-metal pouch cells and secure the practical applications necessary to power this society in a safe manner.

Assessing the Thermal Safety of a Li Metal Solid-State Battery Material Set Using Differential Scanning Calorimetry

At the earliest stage of battery development, differential scanning calorimetry (DSC) of a sample with all battery cell stack materials can provide quantitative data on the reaction thermochemistry. The resulting quantitative thermochemical map of expected reactions upon heating can then guide chemistry and component development toward improved cell safety. In this work, we construct Li0.43CoO2 + C + PVDF|Li6.4La3Zr1.4Ta0.6O12|Li microcell DSC samples with capacity-matched electrodes and test to 500 °C. Notable observations are: (1) ∼74% of the O2 released from the Li0.43CoO2 cathode reacts with C to form CO2 rather than with molten Li to produce Li2O, (2) PVDF pyrolysis (>400 °C) releases HF gas that exothermically reacts with Li to form LiF, and (3) reactions involving oxygen (e.g., CO2 and Li2O formation) account for ∼60% of the total heat released, and reactions involving HF (e.g., LiF formation) account for ∼36% of the total heat released.

High-Safety Lithium-Ion Batteries with Silicon-Based Anodes Enabled by Electrolyte Design

High-energy-density lithium-ion batteries (LIBs) with high safety have long been pursued for extending the cruise range of electric vehicles. Owing to the high gravimetric capacity, silicon is a promising alternative to the convention graphite anode for high-energy LIBs. However, it suffers from intrinsic poor interfacial stability with liquid electrolytes, inevitably increasing the risk of thermal runaway and posing serious safety challenges. In this review, we will focus on mitigating thermal runaway of silicon anodes-based LIBs from the perspective of electrolyte design. First, the thermal runaway mechanism of LIBs is briefly introduced, while the specific thermal failure reactions associated with silicon anodes and electrolytes are discussed in detail. We then summarize the safety countermeasures (e. g., thermally stable solid electrolyte interphase, nonflammable electrolytes, highly stable lithium salts, mitigating electrode crosstalk, and solid-state electrolytes) enabled by customized electrolyte design to address these triggers of thermal runaway. Finally, the remaining unanswered questions regarding the thermal runaway mechanism are presented, and future directions to achieve intrinsically safe electrolytes for silicon-based anodes are prospected. This review is expected to provide insightful knowledge for improving the safety of LIBs with silicon-based anodes.

Effect of Dust and Hot Spots on the Thermal Stability of Laser Sails

Laser sails propelled by gigawatt-scale ground-based laser arrays have the potential to reach relativistic speeds, traversing the solar system in hours and reaching nearby stars in years. Here, we describe the danger interplanetary dust poses to the survival of a laser sail during its acceleration phase. We show through multiphysics simulations how localized heating from a single optically absorbing dust particle on the sail can initiate a thermal runaway process that rapidly spreads and destroys the entire sail. We explore potential mitigation strategies, including increasing the in-plane thermal conductivity of the sail to reduce the peak temperature at hot spots and isolating the absorptive regions of the sail that can burn away individually.

Direct Observation of the Anisotropic Transport Behavior of Li+ in Graphite Anodes and Thermal Runaway Induced by the Interlayer Polarization

Graphite is one of the major anode materials for commercial lithium-ion batteries. Li⁺ transport in a single graphite granule along intra and interlayer modes is a crucial factor for the battery performance. However, direct evidence and visualized details of the Li⁺ transports are hardly provided. Here, we report the direct observation of the anisotropic transport behavior of Li⁺ and investigate the electro-chemo-structure evolution during the lithiation of graphite through both the intra and interlayer pathways via in situ transmission electron microscopy. The in situ experiments of nano batteries give two extreme conditions, in which thermal runaway induced by polarization only occurs along the interlayer, not along the intralayer. The high diffusion energy barrier induced large polarization when the interlayer Li⁺ transport became dominant. The energy of the polarization electric field would be instantaneously released like a short electric pulse, which generated a substantial amount of joule heat and created an extremely high temperature, causing the melting of the tungsten tip. We provide another possible fundamental mechanism of thermal failure in graphite-based Li-ion batteries and hope this insightful work would help the safety management of graphite-based lithium-ion batteries.

Having Your Cake and Eating It Too: Electrode Processing Approach Improves Safety and Electrochemical Performance of Lithium-Ion Batteries

A layered Li[Ni_xCo_yMn_1-x-y]O₂ (NCM)-based cathode is preferred for its high theoretical specific capacity. However, the two main issues that limit its practical application are severe safety issues and excessive capacity decay. A new electrode processing approach is proposed to synergistically enhance the electrochemical and safety performance. The polyimide's (PI) precursor is spin-coated on the LiNi_0.5Co_0.2Mn_0.3O₂ (NCM523) electrode sheet, and the homogeneous sulfonated PI layer is in situ produced by thermal imidization reaction. The PI-spin coated (PSC) layer provides improvements in capacity retention (86.47% vs 53.77% after 150 cycles at 1 C) and rate performance (99.21% enhancement at 5 C) as demonstrated by the NCM523-PSC||Li half-cell. The NCM523-PSC||graphite pouch full cell proves enhanced capacity retention (76.62% vs 58.58% after 500 cycles at 0.5 C) as well. The thermal safety of the NCM523-PSC cathode-based pouch cell is also significantly improved, with the critical temperature of thermal safety T₁ (the beginning temperature of obvious self-heating temperature) and thermal runaway temperature T₂ increased by 60.18 and 44.59 °C, respectively. Mechanistic studies show that the PSC layer has multiple effects as a passivation layer such as isolation of electrode-electrolyte contact, oxygen release suppression, solvation structure tuning, and the decomposition of carbonate solvents as well as LiPF₆ inhibition. This work provides a new path for a cost-effective and scalable design of electrode decoration with synergistic safety-electrochemical kinetics enhancement.

Toward Improving the Thermal Stability of Negative Electrode Materials: Differential Scanning Calorimetry and In Situ High-Temperature X-ray Diffraction/X-ray Absorption Spectroscopy Studies of Li2ZnTi3O8 and Related Compounds

Negative electrode materials with high thermal stability are a key strategy for improving the safety of lithium-ion batteries for electric vehicles without requiring built-in safety devices. To search for crucial clues into increasing the thermal stability of these materials, we performed differential scanning calorimetry (DSC) and in situ high-temperature (HT)-X-ray diffraction (XRD)/X-ray absorption (XAS) up to 450 °C with respect to a solid-solution compound of Li_4/3-2x/3Zn_xTi_5/3-x/3O₄ with 0 ≤ x ≤ 0.5. The DSC profile of fully discharged x = 0.5 (Li₂ZnTi₃O₈) with a LiPF₆-based electrolyte could be divided into three temperature (T) regions: (i) T ≤ 250 °C for ΔH_accumⁱ, (ii) 250 °C < T ≤ 350 °C for ΔH_accumⁱⁱ, and (iii) T > 350 °C for ΔH_accumⁱⁱⁱ, where ΔH_accumⁿ is the accumulated change in enthalpy in region n. The HT-XRD/XAS analyses clarified that ΔH_accumⁱ and ΔH_accumⁱⁱ originated from the decomposition of solid electrolyte interphase (SEI) films and the formation of a LiF phase, respectively. Comparison of the DSC profiles with x = 0 (Li[Li_1/3Ti_5/3]O₄) and graphite revealed the operating voltage, i.e., amount of SEI films, and stability of the crystal lattice play significant roles in the thermal stability of negative electrode materials. Indeed, the highest thermal stability was attained at x = 0.25 using this approach.

In Situ Detecting Thermal Stability of Solid Electrolyte Interphase (SEI)

Solid electrolyte interphase (SEI) plays an important role in regulating the interfacial ion transfer and safety of Lithium-ion batteries (LIBs). It is unstable and readily decomposed releasing much heat and gases and thus triggering thermal runaway. Herein, in situ heating X-ray photoelectron spectroscopy is applied to uncover the inherent thermal decomposition process of the SEI. The evolution of the composition, nanostructure, and the released gases are further probed by cryogenic transmission electron microscopy, and gas chromatography. The results show that the organic components of SEI are readily decomposed even at room temperature, releasing some flammable gases (e.g., H₂ , CO, C₂ H₄ , etc.). The residual SEI after heat treatment is rich in inorganic components (e.g., Li₂ O, LiF, and Li₂ CO₃ ), provides a nanostructure model for a beneficial SEI with enhanced stability. This work deepens the understanding of SEI intrinsic thermal stability, reveals its underlying relationship with the thermal runaway of LIBs, and enlightens to enhance the safety of LIBs by achieving inorganics-rich SEI.

Advanced Nonflammable Organic Electrolyte Promises Safer Li-Metal Batteries: From Solvation Structure Perspectives

Batteries with a Li-metal anode have recently attracted extensive attention from the battery communities owing to their high energy density. However, severe dendrite growth hinders their practical applications. More seriously, when Li dendrites pierce the separators and trigger short circuit in a highly flammable organic electrolyte, the results would be catastrophic. Although the issues of growth of Li dendrites have been almost addressed by various methods, the highly flammable nature of conventional organic liquid electrolytes is still a lingering fear facing high-energy-density Li-metal batteries given the possibility of thermal runaway of the high-voltage cathode. Recently, various kinds of nonflammable liquid- or solid-state electrolytes have shown great potential toward safer Li-metal batteries with minimal detrimental effect on the battery performance or even enhanced electrochemical performance. In this review, recent advances in developing nonflammable electrolyte for high-energy-density Li-metal batteries including high-concentration electrolyte, localized high-concentration electrolyte, fluorinated electrolyte, ionic liquid electrolyte, and polymer electrolyte are summarized. Then, the solvation structure of different kinds of nonflammable liquid and polymer electrolytes are analyzed to provide insight into the mechanism for dendrite suppression and fire extinguishing. Finally, guidelines for future design of nonflammable electrolyte for safer Li-metal batteries are provided.

Sequential Solidification of Metal Powder by a Scanning Microwave Applicator

This study examines the fundamental feasibility of sequential metal-powder solidification by localized microwave-heating (LMH) provided by a scanning, all-solid-state microwave applicator. This continuous process is considered for the additive manufacturing (AM) and 3D printing (3DP) applications of metal parts. In previous studies, we employed LMH for the incremental solidification of small batches of metal powder in a stepwise vertical manner. Here, we study a continuous lateral LMH process, layer by layer, in a fashion similar to laser scanning in powder beds, as performed in common laser-based AM systems. LMH solidification at scanning rates of ~1 mm³/s is obtained in bronze powder using ~0.25-kW microwave power. The effect is studied here by LMH scanning in one lateral dimension (~20-mm long) in layers, each of ~1-4 mm thickness and ~2-4 mm width (mechanically confined). Imperfect solid bars of ~20×4×5 mm³ are obtained with rough surfaces. Their joining in an L shape is also demonstrated. The experimental solidified products are tested, and their hardness and density properties are found to be comparable to laser-based AM products. The capabilities and limitations of the LMH scanning concept for metal-powder solidification are evaluated. The potential feasibility of a solid-state LMH-AM technology is discussed.

In situ chamber for studying battery failure using high-speed synchrotron radiography

The investigation of lithium-ion battery failures is a major challenge for personnel and equipment due to the associated hazards (thermal reaction, toxic gases and explosions). To perform such experiments safely, a battery abuse-test chamber has been developed and installed at the microtomography beamline ID19 of the European Synchrotron Radiation Facility (ESRF). The chamber provides the capability to robustly perform in situ abuse tests through the heat-resistant and gas-tight design for flexible battery geometries and configurations, including single-cell and multi-cell assemblies. High-speed X-ray imaging can be complemented by supplementary equipment, including additional probes (voltage, pressure and temperature) and thermal imaging. Together with the test chamber, a synchronization graphical user interface was developed, which allows an initial interpretation by time-synchronous visualization of the acquired data. Enabled by this setup, new meaningful insights can be gained into the internal processes of a thermal runaway of current and future energy-storage devices such as lithium-ion cells.

Early Braking of Overwarmed Lithium-Ion Batteries by Shape-Memorized Current Collectors

In the context of the constant impending energy crisis, the lithium-ion battery as a burgeoning energy storage means is showing extraordinary talents in many energy relevant investigations. However, fire and explosion would probably occur when the battery is encountered with overheating, at which the shrinking of the separator routinely causes an internal short circuit. Herein, we develop a kind of novel shape-memorized current collector (SMCC), which can successfully brake battery thermal runaway at the battery internal overheating status. Unlike traditional current collectors made of commercial copper foils, SMCC is made of a micropatterned shape memory micron-sized film with copper deposition. SMCC displays ideal conductivity at normal temperatures and turns to be insulative at overheating temperatures. Following this principle, the battery consisting of an SMCC can run normally at temperatures lower than 90 °C, while it quickly achieves self-shutdown before the occurrence of battery combustion and explosion.

Thermal Runaway of Nonflammable Localized High-Concentration Electrolytes for Practical LiNi0.8 Mn0.1 Co0.1 O2 |Graphite-SiO Pouch Cells

With continuous improvement of batteries in energy density, enhancing their safety is becoming increasingly urgent. Herein, practical high energy density LiNi_0.8 Mn_0.1 Co_0.1 O₂ |graphite-SiO pouch cell with nonflammable localized high concentration electrolyte (LHCE) is proposed that presents unique self-discharge characteristic before thermal runaway (TR), thus effectively reducing safety hazards. Compared with the reference electrolyte, pouch cell with nonflammable LHCE can increase self-generated heat temperature by 4.4 °C, increase TR triggering temperature by 47.3 °C, decrease the TR highest temperature by 71.8 °C, and extend the time from self-generated heat to triggering TR by ≈8 h. In addition, the cell with nonflammable LHCE presents superior high voltage cycle stability, attributed to the formation of robust inorganic-rich electrode-electrolyte interphase. The strategy represents a pivotal step forward for practical high energy and high safety batteries.

Chemical Characterization Using Laser-Induced Breakdown Spectroscopy of Products Released from Lithium-Ion Battery Cells at Thermal Runaway Conditions

Laser-induced breakdown spectroscopy (LIBS) was used to characterize the ejecta released by lithium-ion (Li-ion) cells at thermal runaway conditions. Commercial AAA-size, rechargeable, 3.7 V, 350 mAh, Li-ion battery cells were heated in a N₂ -atmosphere tubular chamber up to about 165 ℃ to induce thermal decomposition. Through measurements of the chamber internal temperature and LIBS emission intensities over, time the onset temperature of thermal runaway (≈143 ℃) and the duration of the cells outgassing (>40 minutes) were determined. Relatively high-intensity atomic emissions from C, F, H, Li, Na, and P were detected at different times during the heating experiments. The detection of analytes such as C and H was continuous over time. On the contrary, detection of F, Li, Na, and P was more irregular, indicating the presence of solid-phase analytes or analyte-bearing particles. A calibration scheme for estimation of the total mass/volume concentration of all carbon-based species sampled within the laser-induced plasma was developed.

Thermal-Switchable, Trifunctional Ceramic-Hydrogel Nanocomposites Enable Full-Lifecycle Security in Practical Battery Systems

Thermal runaway (TR) failures of large-format lithium-ion battery systems related to fires and explosions have become a growing concern. Here, we design a smart ceramic-hydrogel nanocomposite that provides integrated thermal management, cooling, and fire insulation functionalities and enables full-lifecycle security. The glass-ceramic nanobelt sponges exhibit high mechanical flexibility with 80% reversible compressibility and high fatigue resistance, which can firmly couple with the polymer-nanoparticle hydrogels and form thermal-switchable nanocomposites. In the operating mode, the high enthalpy of the nanocomposites enables efficient thermal management, thereby preventing local temperature spikes and overheating under extremely fast charging conditions. In the case of mechanical or thermal abuse, the stored water can be immediately released, leaving behind a highly flexible ceramic matrix with low thermal conductivity (42 mW m^-1 K^-1 at 200 °C) and high-temperature resistance (up to 1300 °C), thus effectively cooling the TR battery and alleviating the devastating TR propagation. The versatility, self-adaptivity, environmental friendliness, and manufacturing scalability make this material highly attractive for practical safety assurance applications.

Computational Design to Suppress Thermal Runaway of Li-Ion Batteries via Atomic Substitutions to Cathode Materials

The cathode material of a lithium-ion battery is a key component that affects durability, capacity, and safety. Compared to the LiCoO2 cathode material (the reference standard for these properties), LiNiO2 can extract more Li at the same voltage and has therefore attracted considerable attention as a material that can be used to obtain higher capacity. As a trade-off, it undergoes pyrolysis relatively easily, leading to ignition and explosion hazards, which is a challenge associated with the application of this compound. Pyrolysis has been identified as a structural phase transformation of the layered rocksalt structure → spinel → cubic rocksalt. Partial substitution of Ni with various elements can reportedly suppress the transformation and, hence, the pyrolysis. It remains unclear which elemental substitutions inhibit pyrolysis and by what mechanism, leading to costly material development that relies on empirical trial and error. In this study, we developed several possible reaction models based on existing reports, estimated the enthalpy change associated with the reaction by ab initio calculations, and identified promising elemental substitutions. The possible models were narrowed down by analyzing the correlations of the predicted dependence of the reaction enthalpies on elemental substitutions, compared between different reaction models. According to this model, substitution by P and Ta affords the highest enthalpy barrier between the initial (layered rocksalt) and the final (cubic rocksalt) structures but promotes the initial transformation to spinel as a degradation. Substitution by W instead generates the barrier to the final (preventing dangerous incidents) process, as well as for the initial degradation to spinel; therefore, it is a promising strategy to suppress the predicted pyrolysis.

Impedimetric Chemosensing of Volatile Organic Compounds Released from Li-Ion Batteries

Detection of toxic and flammable gases and volatile organic compounds (VOCs) released from Li-ion batteries during thermal runaway can generate an early warning. A submicron (∼0.15 μm)-thick poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) sensor film is coated on a platinum electrode through a facile aqueous dispersion. The resulting sensor reliably detected different volatile organic compounds (VOCs) released during the early stages of thermal runaway of lithium-ion batteries (LIBs) even at low concentrations. The single-electrode sensor utilizes impedance spectroscopy to measure ethyl methyl carbonate and methyl formate concentrations at 5, 15, and 30 ppm independently and in various combinations using ethanol as a reference. In contrast to DC resistance measurement, which provides a single parameter, impedance spectroscopy provides a wealth of information, including impedance and phase angle at multiple frequencies as well as fitted charge transfer resistance and constant-phase elements. Different analytes influence the measurement of different parameters to varying degrees, enabling distinction using a single sensing material. The response time for ethyl methyl carbonate was measured to be 6 s. Three principal components (PCs) preserve more than 95% of information and efficiently enable discrimination of different classes of analytes. Application of low-power PEDOT:PSS-based gas sensors will facilitate cost-effective early detection of VOCs and provide early warning to battery management systems (BMS), potentially mitigating catastrophic thermal runaway events.

Bioinspired Thermal Runaway Retardant Capsules for Improved Safety and Electrochemical Performance in Lithium-Ion Batteries

Vigorous development of electric vehicles is one way to achieve global carbon reduction goals. However, fires caused by thermal runaway of the power battery has seriously hindered large-scale development. Adding thermal runaway retardants (TRRs) to electrolytes is an effective way to improve battery safety, but it often reduces electrochemical performance. Therefore, it is difficult to apply in practice. TRR encapsulation is inspired by the core-shell structures such as cells, seeds, eggs, and fruits in nature. In these natural products, the shell isolates the core from the outside, and has to break as needed to expose the core, such as in seed germination, chicken hatching, etc. Similarly, TRR encapsulation avoids direct contact between the TRR and the electrolyte, so it does not affect the electrochemical performance of the battery during normal operation. When lithium-ion battery (LIB) thermal runaway occurs, the capsules release TRRs to slow down and even prevent further thermal runaway. This review aims to summarize the fundamentals of bioinspired TRR capsules and highlight recent key progress in LIBs with TRR capsules to improve LIB safety. It is anticipated that this review will inspire further improvement in battery safety, especially for emerging LIBs with high-electrochemical performance.

Multiscale Understanding of Surface Structural Effects on High-Temperature Operational Resiliency of Layered Oxide Cathodes

The worldwide energy demand in electric vehicles and the increasing global temperature have called for development of high-energy and long-life lithium-ion batteries (LIBs) with improved high-temperature operational resiliency. However, current attention has been mostly focused on cycling aging at elevated temperature, leaving considerable gaps of knowledge in the failure mechanism, and practical control of abusive calendar aging and thermal runaway that are highly related to the eventual operational lifetime and safety performance of LIBs. Herein, using a combination of various in situ synchrotron X-ray and electron microscopy techniques, a multiscale understanding of surface structure effects involved in regulating the high-temperature operational tolerance of polycrystalline Ni-rich layered cathodes is reported. The results collectively show that an ultraconformal poly(3,4-ethylenedioxythiophene) coating can effectively prevent a LiNi_0.8 Co_0.1 Mn_0.1 O₂ cathode from undergoing undesired phase transformation and transition metal dissolution on the surface, atomic displacement, and dislocations within primary particles, intergranular cracking along the grain boundaries within secondary particles, and intensive bulk oxygen release during high state-of-charge and high-temperature aging. The present work highlights the essential role of surface structure controls in overcoming the multiscale degradation pathways of high-energy battery materials at extreme temperature.

Simultaneously Blocking Chemical Crosstalk and Internal Short Circuit via Gel-Stretching Derived Nanoporous Non-Shrinkage Separator for Safe Lithium-Ion Batteries

The separator, an ionic permeable and electronic insulating membrane between cathode and anode, plays a crucial role in the electrochemical and safety performance of batteries. However, commercial polyolefin separators not only suffer from inevitable thermal shrinkage at elevated temperature, but also fail to inhibit the hidden chemical crosstalk of reactive gases such as O₂ , leading to often reported thermal runaway (TR) and hence preventing large-scale implementation of high-energy-density lithium-ion batteries. Herein, a nanoporous non-shrinkage separator (GS-PI) is fabricated via a novel gel-stretching orientation approach to eliminate TR. In situ synchrotron small angle X-ray scattering during heating clearly shows that the as-prepared thin GS-PI separator exhibits superior mechanical tolerance at high temperature, thus effectively preventing internal short circuit. Meanwhile, the unique nanoporous structure design further blocks chemical crosstalk and the associated exothermic reactions. Accelerating rate calorimetry tests reveal that the practical 1 Ah LiNi_0.6 Co_0.2 Mn_0.2 O₂ (NCM622)/graphite pouch cell using GS-PI nanoporous separator show a maximum temperature rise (dT/dt_max ) of only 3.7 °C s^-1 compared to 131.6 °C s^-1 in the case of Al₂ O₃ @PE macroporous separator. Moreover, despite the reduced pore size, the GS-PI separator demonstrates better cycling stability than conventional Al₂ O₃ @PE separator at high temperature without sacrificing specific capacity and rate capability.

Deformation and Failure Properties of High-Ni Lithium-Ion Battery under Axial Loads

To explore the failure modes of high-Ni batteries under different axial loads, quasi-static compression and dynamic impact tests were carried out. The characteristics of voltage, load, and temperature of a battery cell with different states of charge (SOCs) were investigated in quasi-static tests. The mechanical response and safety performance of lithium-ion batteries subjected to axial shock wave impact load were also investigated by using a split Hopkinson pressure bar (SHPB) system. Different failure modes of the battery were identified. Under quasi-static axial compression, the intensity of thermal runaway becomes more severe with the increase in SOC and loading speed, and the time for lithium-ion batteries to reach complete failure decreases with the increase in SOC. In comparison, under dynamic SHPB experiments, an internal short circuit occurred after impact, but no violent thermal runaway was observed.

Achieving a Stable Solid Electrolyte Interphase and Enhanced Thermal Stability by a Dual-Functional Electrolyte Additive toward a High-Loading LiNi0.8Mn0.1Co0.1O2 /Lithium Pouch Battery

Li metal batteries with high-capacity cathodes emerge as promising candidates for next-generation battery technologies. However, the poor reversibility of the Li deposition/stripping process severely reduces its lifespan, and safety also remains a major issue for the Li metal anodes. Herein, we propose (ethoxy)-penta-fluoro-cyclo-triphosphazene (DFA) as a dual-functional electrolyte additive to solve the engineering problem of balancing the cycle life and thermal stability of Li metal batteries. The NCM811/lithium metal pouch batteries (2900 mA h) are assembled using the commercial high areal capacity cathode (3.5 mA h cm^-2). Compared with the NCM811/Li batteries without DFA, the heat generation and heat generation power of lithium metal batteries with DFA are significantly reduced by half during charging. Moreover, the NCM811/Li pouch batteries with DFA show excellent stability in both hot-oven and adiabatic rate calorimeter experiments. Furthermore, a nonlinear phase field simulation is carried out for mechanism investigation, which confirms that the stable solid electrolyte interphase formed by DFA will improve the cycle life of the NCM811/Li pouch. The DFA is verified to be an effective additive to improve the cycle stability and safety simultaneously, providing new opportunities for developing high energy density Li metal batteries.

Electric Scooter Battery Detonation: A Case Series And Review Of Literature

Since 2016 there has been a 20-fold increase in known burns injury from personal mobility device (PMD) related fires. The root cause is the failure of high-density lithium ion (Li-ion) battery packs powering the PMDs. This failure process, known as thermal runaway, is well documented in applied science journals. Importantly, the liberation of hydrogen fluoride from failing Li-ion batteries may contribute to unrecognized chemical burns. A clinical gap in knowledge exists in the understanding of the explosive nature of Li-ion batteries. We reviewed the electrochemical pathophysiology of a failing Li-ion cell as it impacts clinical management of burn injuries. This retrospective study was carried out in two major institutions in Singapore. All admitted PMD-related burns and follow up appointments were captured and reviewed from 2016 - 2020. Thirty patients were admitted to tertiary hospitals, 43% of patients were in the pediatric population and 57% were adult patients, aged from 0.3 to 77 years. TBSA of burns ranged from 0 to 80% with a mean 14.5%. 73% of cases presented with inhalation injury, 8 of whom did not suffer any cutaneous burns. 50% of patients sustained both cutaneous and inhalation burn injuries. 27% of patients sustained major burns of >20% TBSA, with 2 in the pediatric group. Mortali ty rate was 10% from PMD-related fires. This cause of burn injury has proven to be fa tal. Prevention of PMD-related fires by ensuring proper battery utilization, adherence to PMD sanctions for battery standards and public education is vital to reducing the morbidity and mortality of this unique type of thermal injury.

Thermal Behavior of Li1+x[Li1/3Ti5/3]O4 and a Proof of Concept for Sustainable Batteries

An in-depth understanding of the thermal behavior of lithium-ion battery materials is valuable for two reasons: one is to devise strategies for inhibiting the risk of catastrophic thermal runaway and the other is to respond to the increasing demand for sustainable batteries using a direct regeneration method. Li_1+x[Li_1/3Ti_5/3]O₄ (LTO) is regarded as a suitable negative electrode under the type of severe conditions that cause this thermal runaway, such as in ignition systems for automobiles. Thus, in this study, we used differential scanning calorimetry to systematically analyze lithiated LTO combined with ex situ and in situ high-temperature X-ray diffraction measurements. The observed thermal reactions with a LiPF₆-based electrolyte were divided into three processes: (i) the decomposition of the initially formed solid electrolyte interphase below 200 °C, (ii) the formation of a LiF phase at 200 °C ≤ T ≤ 340 °C, and (iii) the formation of a TiO₂ phase at T > 340 °C. Because the enthalpy change in process (ii) mainly contributed to the total heat generation, fluorine-free Li salts and/or stabilization of the LTO lattice may be effective in coping with the thermal runaway. Even in various lithiated states, a direct regeneration method returned the discharge capacity of LTO to ∼90% of its initial value, if we ignore the contributions from the electrochemically inactive LiF and TiO₂ rutile phases. Hence, it can be concluded that the recycling performance of LTO is far superior to those of lithium transition metal oxides for a positive electrode, whose delithiated states easily convert into electrochemical-inactive phases at high temperatures.

The fire risk of portable batteries in their end-of-life: Investigation of the state of charge of waste lithium-ion batteries in Austria

The increased utilisation of lithium-ion batteries in the last years does not come without cost. Due to thermal runaway and exothermic degradation reactions, portable batteries pose enormous risks to waste management systems and infrastructure in their end-of-life phase. All over Europe, the number of waste fires caused by lithium-ion batteries are rising. The risk of a battery fire is mainly influenced by the probability and severity of a thermal runaway or exothermic degradation, which depends on the current state of charge (SOC) of the respective battery. In order to determine the distribution of the SOC which is one of the main influence factors to waste fires caused by lithium-ion batteries, 980 waste battery cells were representatively sampled, manually dismantled and analysed using a prototypic laboratory test stand. Approximately 24% of the analysed cells and batteries had a residual SOC of at least 25%, and approximately 12% had a residual SOC of at least 50%. Hence, approximately every fourth to eighth portable battery threatens to cause a waste fire when critically damaged. Furthermore, a distinct relationship between the actual cell voltage and the residual SOC was found for end-of-life portable batteries.

Experimental Study on Thermal Runaway Process of 18650 Lithium-Ion Battery under Different Discharge Currents

Lithium-ion batteries (LIBs) subjected to external heat may be prone to failure and cause catastrophic safety issues. In this work, experiments were conducted to investigate the influence of discharge current on the thermal runaway process under thermal abuse. The calibrated external heat source (20 W) and discharge currents from 1 to 6 A were employed to match the thermal abuse conditions in an operational state. The results indicated that the key parameters during the failure process, such as the total mass loss, the onset temperatures of safety venting and thermal runaway, and the peak temperature, are ultimately determined by the capacity inside the battery, and the discharge current can hardly change it. However, discharge currents can produce extra energy to accelerate the thermal runaway process. Compared with the battery in an open circuit, the onset time of thermal runaway was reduced by 7.4% at 6 A discharge. To quantify the effect of discharge current, the total heat generation by discharge current was calculated. The results show that a heat generation of 1.6 kJ was produced when the battery was discharged at 6 A, which could heat the cell to 34 °C (neglect of heat loss). This study simulates the failure process of the LIB in the operational state, which is expected to help the safety application of LIB and improve the reliability of the battery management system.

Comprehensive Investigation of a Slight Overcharge on Degradation and Thermal Runaway Behavior of Lithium-Ion Batteries

Overcharge is a hazardous abuse condition that has dominant influences on cell performance and safety. This work, for the first time, comprehensively investigates the impact of different overcharge degrees on degradation and thermal runaway behavior of lithium-ion batteries. The results indicate that single overcharge has little influence on cell capacity, while it severely degrades thermal stability. Degradation mechanisms are investigated by utilizing the incremental capacity-differential voltage and relaxation voltage analyses. During the slight overcharge process, the conductivity loss and the loss of lithium inventory always occur; the loss of active material starts happening only when the cell is overcharged to a certain degree. Lithium plating is the major cause for the loss of lithium inventory, and an interesting phenomenon that the arrival time of the dV/dt peak decreases linearly with the increase of the overcharge degree is found. The cells with different degrees of overcharge exhibit a similar behavior during adiabatic thermal runaway. Meanwhile, the relationship between sudden voltage drop and thermal runaway is further established. More importantly, the characteristic temperature of thermal runaway, especially the self-heating temperature (T₁), decreases severely along with overcharging, which means that a slight overcharge severely decreases the cell thermal stability. Further, post-mortem analysis is conducted to investigate the degradation mechanisms. The mechanism of the side reactions caused by a slight overcharge on the degradation performance and thermal runaway characteristics is revealed.

Enhancing the Thermal Stability of NASICON Solid Electrolyte Pellets against Metallic Lithium by Defect Modification

All-solid-state batteries (ASSBs) are expected to address the battery safety issues fundamentally by replacing the flammable electrolyte with solid electrolytes (SEs). However, recent studies report that the thermal runaway happened for NASICON-type SEs when they contact with Li metal at high temperature and indicate that the ASSBs may not be totally safe. Here, the thermal stability of a NASICON-type Li_1.4Al_0.4Ti_1.6(PO₄)₃ (LATP) SE pellet against metallic lithium is quantified in a quasi-practical situation. Accelerated thermal runaway of the LATP pellet compared to LATP powder is observed when they contact with lithium. Combining electrochemical impedance spectroscopy and X-ray computed tomography analysis, lithium penetration into the pellet at high temperature has been observed. The penetrated lithium without surface impurities and the high reactivity of LATP at defect sites (atomic structural defects, cracks, voids, etc.) lead to higher interfacial reactivity and earlier thermal runaway. By adding LiPO₂F₂ to modify those defect sites of the LATP pellet and impede the lithium/SE interfacial reactions, the thermal runaway can be remarkably delayed. This work elucidates the thermal runaway behaviors of Li/LATP pellets in a quasi-practical environment, provides new information about safety issues of ASSBs, and inspires future investigations into this urgent-needed area.

Fiber Optic Sensing Technologies for Battery Management Systems and Energy Storage Applications

Applications of fiber optic sensors to battery monitoring have been increasing due to the growing need of enhanced battery management systems with accurate state estimations. The goal of this review is to discuss the advancements enabling the practical implementation of battery internal parameter measurements including local temperature, strain, pressure, and refractive index for general operation, as well as the external measurements such as temperature gradients and vent gas sensing for thermal runaway imminent detection. A reasonable matching is discussed between fiber optic sensors of different range capabilities with battery systems of three levels of scales, namely electric vehicle and heavy-duty electric truck battery packs, and grid-scale battery systems. The advantages of fiber optic sensors over electrical sensors are discussed, while electrochemical stability issues of fiber-implanted batteries are critically assessed. This review also includes the estimated sensing system costs for typical fiber optic sensors and identifies the high interrogation cost as one of the limitations in their practical deployment into batteries. Finally, future perspectives are considered in the implementation of fiber optics into high-value battery applications such as grid-scale energy storage fault detection and prediction systems.

Influence of Elastic Scattering on Electron Swarm Distribution in Electrified Gases

The propagation of energetic electrons through air is one key component in the generation of high-energy atmospheric phenomena such as lightning-generated X-ray bursts, terrestrial gamma ray flashes (TGFs), and gamma ray glows. We show here that models for this propagation can be considerably affected by the parameterization of the differential cross section of elastic scattering of electrons on the molecular components of air. We assess existing parameterizations and propose a more accurate one that builds upon the most up-to-date measurements. Then we conclude that by overweighting the forward scattering probability, previous works may have overestimated the production of runaway electrons under high electric fields close to the thermal runaway threshold.

Projectile Wound to Head from Modified Electronic Cigarette Explosion

One of the dangers of a rapidly growing technology industry is the risk involved in being intimately close to lithium-ion batteries. When exposed to improper conditions, lithium-ion batteries in a variety of devices have been reported to ignite and, in some cases, explode. With the rise of electronic cigarette use and modifications, the lithium-ion batteries in these devices are subject to a higher risk of malfunction. This is a retrograde analysis of a 38-year-old man who experienced fatal penetrating head trauma while using a modified electronic cigarette device. The findings suggest that the trauma from the explosion was caused by the thermal runaway of the lithium-ion battery in the modified e-cigarette.

In Operando Calorimetric Measurements for Activated Carbon Electrodes in Ionic Liquid Electrolytes under Large Potential Windows

This study aims to investigate the effect of the potential window on heat generation in carbon-based electrical double layer capacitors (EDLCs) with ionic-liquid (IL)-based electrolytes using in operando calorimetry. The EDLCs consisted of two identical activated-carbon electrodes with either neat 1-butyl-1-methylpyrrolidinium bis(trifluoromethane-sulfonyl)imide ([Pyr₁₄ ][TFSI]) electrolyte or 1.0 m [Pyr₁₄ ][TFSI] in propylene carbonate (PC) as electrolyte. The instantaneous heat generation rate at each electrode was measured under galvanostatic cycling for different potential windows ranging from 1 to 4 V. First, the heat generation rates at the positive and negative electrodes differed significantly in neat IL owing to the differences in the ion sizes and diffusion coefficients. However, these differences were minimized when the IL was diluted in PC. Second, for EDLC in neat [Pyr₁₄ ][TFSI] at high potential window (4 V), a pronounced endothermic peak was observed at the beginning of the charging step at the positive electrode owing to TFSI^- intercalation in the activated carbon. On the other hand, for EDLC in 1.0 m [Pyr₁₄ ][TFSI] in PC at potential window above 3 V, an endothermic peak was observed only at the negative electrode owing to the decomposition of PC. Third, for both neat and diluted [Pyr₁₄ ][TFSI] electrolytes, the irreversible heat generation rate increased with increasing potential window and exceeded Joule heating. This was attributed to the effect of potential-dependent charge redistribution resistance. A further increase in the irreversible heat generation rate was observed for the largest potential windows owing to the degradation of the PC solvent. Finally, for both types of electrolyte, the reversible heat generation rate increased with increasing potential window because of the increase in the amount of ion adsorbed/desorbed at the electrode/electrolyte interface.

[Volcano in the Pocket: Danger Induced by Electronic Cigarettes]

Volcano in the Pocket: Danger Induced by Electronic Cigarettes Abstract. We report two cases of male patients with deep second-degree burns at the lower extremities after thermal runaway of lithium-ion-batteries, which were carried in their trouser pockets as spare batteries for their electronic cigarettes. Both patients were treated according to the official burns guidelines. Here we would like to focus on the fact that irrigation with water is not recommended as the initial treatment for chemical burns caused by lithium. Currently this is not mentioned in the official burns guidelines.

Stabilizing Polyether Electrolyte with a 4 V Metal Oxide Cathode by Nanoscale Interfacial Coating

Safety is critical to developing next-generation batteries with high-energy density. Polyether-based electrolytes, such as poly(ethylene oxide) and poly(ethylene glycol) (PEG), are attractive alternatives to the current flammable liquid organic electrolyte, since they are much more thermally stable and compatible with high-capacity lithium anode. Unfortunately, they are not stable with 4 V Li(Ni_xMn_yCo_1-x-y)O₂ (NMC) cathodes, hindering them from application in batteries with high-energy density. Here, we report that the compatibility between PEG electrolyte and NMC cathodes can be significantly improved by forming a 2 nm Al₂O₃ coating on the NMC surface. This nanoscale coating dramatically changes the composition of the cathode electrolyte interphase and thus stabilizes the PEG electrolyte with the NMC cathode. With Al₂O₃, the capacity remains at 84.7% after 80 cycles and 70.3% after 180 cycles. In contrast, the capacity fades to less than 50% after only 20 cycles in bare NMC electrodes. This study opens a new opportunity to develop safe electrolyte for lithium batteries with high-energy density.

E-Cigarette Battery Explosions: Review of the Acute Management of the Burns and the Impact on Our Population

Electronic cigarettes, also known as e-cigarettes (E-cig), are lithium-battery-powered devices, which became available for sale in the United States in 2017. It has gained significant popularity among younger-generation tobacco smokers due to its advertisement as a non-toxic inhalation property and a potential smoking-cessation aid. The US Food and Drug Administration (FDA) has been regulating e-cigarettes as tobacco products and not as drug-delivery devices, as many medical experts think it should be categorized. In the last few years, the medical community has encountered increasing episodes of burn injuries secondary to e-cigarette battery explosion. Explosions occur through a process known as a "thermal runaway.” This process occurs when the battery overheats and the internal battery temperature increases dangerously high, to the point of inner fire and explosion. Overcharge, puncture, external heat, short circuit, amongst others, are conditions that cause a “thermal runaway.”

This is a retrospective review and analysis of six patients with superficial, partial, and full-thickness burn injuries related to e-cigarette battery explosions managed at Johns Hopkins Bayview Burn Center over the course of one year. Lund-Browder diagrams and calculations were used to assess the total body surface area (TBSA) burns. Laser Doppler imaging (LDI) was used to evaluate the indeterminate depth of the burn.

Only one of our six patients required tangential excision and skin grafting. The rest of our patients were treated conservatively with complex wound care, which included the mixed combination of topical collagenase and bacitracin, collagenase and mafenide, or silver sulfadiazine as a single-agent treatment with an excellent response. Five patients were discharged home within a week, including the patient who required operative excision and auto-grafting. One patient stayed for eight days for pain control and complex wound care.

Our experience with these burns has been similar to what is previously reported. Most of these burns are managed with complex wound care without any surgical interventions. The e-cigarette batteries seem more prone to failure due to an inherent weakness in their structural design. This makes them particularly susceptible to the “thermal runaway.” Therefore, we recognized the need to expand the regulation and control of the quality of these devices. Prevention of these burns will require continuing education for the community on the use of E-cig. products and its potential hazardous implications.

New efforts should be made to educate the community and healthcare providers regarding the potential hazardous implication of carrying these batteries. Also, there is insufficient data to support or deny the long-term health effects of using e-cigarettes.

Thermal-Responsive Polymers for Enhancing Safety of Electrochemical Storage Devices

Thermal runway constitutes the most pressing safety issue in lithium-ion batteries and supercapacitors of large-scale and high-power density due to risks of fire or explosion. However, traditional strategies for averting thermal runaway do not enable the charging-discharging rate to change according to temperature or the original performance to resume when the device is cooled to room temperature. To efficiently control thermal runaway, thermal-responsive polymers provide a feasible and reversible strategy due to their ability to sense and subsequently act according to a predetermined sequence when triggered by heat. Herein, recent research progress on the use of thermal-responsive polymers to enhance the thermal safety of electrochemical storage devices is reviewed. First, a brief discussion is provided on the methods of preventing thermal runaway in electrochemical storage devices. Subsequently, a short review is provided on the different types of thermal-responsive polymers that can efficiently avoid thermal runaway, such as phase change polymers, polymers with sol-gel transitions, and polymers with positive temperature coefficients. The results represent the important development of thermal-responsive polymers toward the prevention of thermal runaway in next-generation smart electrochemical storage devices.

1/2018)

At a critical temperature, active materials within Li‐ion batteries break down, generating heat and gas. Thermal runaway occurs when this process accelerates after the temperature of the cell begins to rise, leading to hazardous failure mechanisms such as the cell bursting. In article number 1700369, Paul R. Shearing and co‐workers use high‐speed X‐ray imaging to capture and characterize such high risk mechanisms in commercial cell designs.

Identifying the Cause of Rupture of Li-Ion Batteries during Thermal Runaway

As the energy density of lithium-ion cells and batteries increases, controlling the outcomes of thermal runaway becomes more challenging. If the high rate of gas generation during thermal runaway is not adequately vented, commercial cell designs can rupture and explode, presenting serious safety concerns. Here, ultra-high-speed synchrotron X-ray imaging is used at >20 000 frames per second to characterize the venting processes of six different 18650 cell designs undergoing thermal runaway. For the first time, the mechanisms that lead to the most catastrophic type of cell failure, rupture, and explosion are identified and elucidated in detail. The practical application of the technique is highlighted by evaluating a novel 18650 cell design with a second vent at the base, which is shown to avoid the critical stages that lead to rupture. The insights yielded in this study shed new light on battery failure and are expected to guide the development of safer commercial cell designs.

Electro-Thermal Model of Threshold Switching in TaOx-Based Devices

Pulsed and quasi-static current-voltage (I-V) characteristics of threshold switching in TiN/TaO_x/TiN crossbar devices were measured as a function of stage temperature (200-495 K) and oxygen flow during the deposition of TaO_x. A comparison of the pulsed and quasi-static characteristics in the high resistance part of the I-V revealed that Joule self-heating significantly affected the current and was a likely source of negative differential resistance (NDR) and thermal runaway. The experimental quasi-static I-V's were simulated using a finite element electro-thermal model that coupled current and heat flow and incorporated an external circuit with an appropriate load resistor. The simulation reproduced the experimental I-V including the OFF-state at low currents and the volatile NDR region. In the NDR region, the simulation predicted spontaneous current constriction forming a small-diameter hot conducting filament with a radius of 250 nm in a 6 μm diameter device.

Experimental Study of Thermal Runaway Process of 18650 Lithium-Ion Battery

This study addresses the effects of the SOC (State of Charge) and the charging–discharging process on the thermal runaway of 18650 lithium-ion batteries. A series of experiments were conducted on an electric heating and testing apparatus. The experimental results indicate that 6 W is the critical heating power for 40% SOC. With a 20 W constant heating rate, the thermal runaway initial temperature of the lithium-ion battery decreases with the increasing SOC. The final thermal runaway temperature increases with the SOC when the SOC is lower than 80%. However, a contrary conclusion was obtained when the SOC was higher than 80%. Significant mass loss, accompanied by an intense exothermic reaction, took place under a higher SOC. The critical charging current, beyond which the thermal runaway occurs, was found to be 2.6 A. The thermal runaway initial temperature decreases with the increasing charging current, while the intensity of the exothermic reaction varies inversely. Mass ejection of gas and electrolytes exists during thermal runaway when the charging current is higher than 10.4 A, below which only a large amount of gas is released. The thermal runaway initial temperature of discharging is higher than that of non-discharging.

Role of Amines in Thermal-Runaway-Mitigating Lithium-Ion Battery

Benzylamine (BA), dibenzylamine (DBA), and trihexylamine (THA) are investigated as thermal-runaway retardants (TRR) for lithium-ion batteries (LIBs). In a LIB, TRR is packaged separately and released when internal shorting happens, so as to suppress exothermic reactions and slow down temperature increase. THA is identified as the most efficient TRR. Upon nail penetration, 4 wt % THA can reduce the peak temperature by nearly 50%. The working mechanisms of the three amines are different: THA is highly wettable to the separator and immiscible with the electrolyte, and therefore, it blocks lithium-ion (Li⁺) transport. BA and DBA decrease the ionic conductivity of electrolyte and increase the charge transfer resistance. All three amines react with charged electrodes; the reactions of DBA and THA do not have much influence on the overall heat generation, while the reaction of BA cannot be ignored.

Self-Protection of Electrochemical Storage Devices via a Thermal Reversible Sol-Gel Transition

Thermal self-protected intelligent electrochemical storage devices are fabricated using a reversible sol-gel transition of the electrolyte, which can decrease the specific capacitance and increase and enable temperature-dependent charging and discharging rates in the device. This work represents proof of a simple and useful concept, which shows tremendous promise for the safe and controlled power delivery in electrochemical devices.

An elementary model for autoignition of laminar jets

In this paper, we formulate and analyse an elementary model for autoignition of cylindrical laminar jets of fuel injected into an oxidizing ambient at rest. This study is motivated by renewed interest in analysis of hydrothermal flames for which such configuration is common. As a result of our analysis, we obtain a sharp characterization of the autoignition position in terms of the principal physical and geometrical parameters of the problem.