The rate of electric vehicle (EV) adoption, powered by the Li-ion battery, has grown exponentially; largely driven by technological advancements, consumer demand, and global initiatives to reduce carbon emissions. As a result, it is imperative to understand the state of stability (SoS) of the cells inside an EV battery pack. That understanding will enable the warning of or prevention against catastrophic failures that can lead to serious injury or even, loss of life. The present work explores rapid electrochemical impedance spectroscopy (EIS) coupled with gas sensing technology as diagnostics to monitor cells and packs for failure markers. These failure markers can then be used for onboard assessment of SoS. Experimental results explore key changes in single cells and packs undergoing thermal or electrical abuse. Rapid EIS showed longer warning times, followed by VOC sensors, and then H2 sensors. While rapid EIS gives the longest warning time, with the failure marker often appearing before the cell vents, the reliability of identifying impedance changes in single cells within a pack decreases as the pack complexity increases. This provides empirical evidence to support the significant role that cell packaging and battery engineering intricacies play in monitoring the SoS.
As large systems of Li-ion batteries are being increasingly deployed, the safety of such systems must be assessed. Due to the high cost of testing large systems, it is important to extract key safety information from any available experiments. Developing validated predictive models that can be exercised at larger scales offers an opportunity to augment experimental data In this work, experiments were conducted on packs of three Li-ion pouch cells with different heating rates and states of charge (SOC) to assess the propagation behavior of a module undergoing thermal runaway. The variable heating rates represent slow or fast heating that a module may experience in a system. As the SOC decreases, propagation slows down and eventually becomes mitigated. It was found that the SOC boundary between propagation and mitigation was higher at a heating rate of 50 °C/min than at 10 °C/min for these cells. However, due to increased pre-heating at the lower heating rate, the propagation speed increased. Simulations were conducted with a new intra-particle diffusion-limited reaction model for a range of anode particle sizes. Propagation speeds and onset times were generally well predicted, and the variability in the propagation/mitigation boundary highlighted the need for greater uncertainty quantification of the predictions.
All-solid-state batteries are often assumed to be safer than conventional Li-ion ones. In this work, we present the first thermodynamic models to quantitatively evaluate solid-state and Li-ion battery heat release under several failure scenarios. The solid-state battery analysis is carried out with an Li7La3Zr2O12 solid electrolyte but can be extended to other configurations using the accompanying spreadsheet. We consider solid-state batteries that include a relatively small amount of liquid electrolyte, which is often added at the cathode to reduce interfacial resistance. While the addition of small amounts of liquid electrolyte increases heat release under specific failure scenarios, it may be small enough that other considerations, such as manufacturability and performance, are more important commercially. We show that short-circuited all-solid-state batteries can reach temperatures significantly higher than conventional Li-ion, which could lead to fire through flammable packaging and/or nearby materials. Our work highlights the need for quantitative safety analyses of solid-state batteries.
Concerns about the safety of lithium-ion batteries have motivated numerous studies on the response of fresh cells to abusive, off-nominal conditions, but studies on aged cells are relatively rare. This perspective considers all open literature on the thermal, electrical, and mechanical abuse response of aged lithium-ion cells and modules to identify critical changes in their behavior relative to fresh cells. We outline data gaps in aged cell safety, including electrical and mechanical testing, and module-level experiments. Understanding how the abuse response of aged cells differs from fresh cells will enable the design of more effective energy storage failure mitigation systems.
This report describes recommended abuse testing procedures for rechargeable energy storage systems (RESSs) for electric vehicles. This report serves as a revision to the USABC Electrical Energy Storage System Abuse Test Manual for Electric and Hybrid Electric Vehicle Applications (SAND99-0497).
This work uses accelerating rate calorimetry to evaluate the impact of cell chemistry, state of charge, cell capacity, and ultimately cell energy density on the total energy release and peak heating rates observed during thermal runaway of Li-ion batteries. While the traditional focus has been using calorimetry to compare different chemistries in cells of similar sizes, this work seeks to better understand how applicable small cell data is to understand the thermal runaway behavior of large cells as well as determine if thermal runaway behaviors can be more generally tied to aspects of lithium-ion cells such as total stored energy and specific energy. We have found a strong linear correlation between the total enthalpy of the thermal runaway process and the stored energy of the cell, apparently independent of cell size and state of charge. We have also shown that peak heating rates and peak temperatures reached during thermal runaway events are more closely tied to specific energy, increasing exponentially in the case of peak heating rates.