As modern technology continues to advance rapidly, lithium-ion batteries become a critical component of the world around us. Because of their lightweight design, rechargeable functionality, and wide temperature ranges, they will only become more relied upon in the years to come.
Today, lithium-ion batteries are used in consumer electronics, micro-mobility, electric vehicles, medical devices, aviation, and dozens more applications.
However, in order to understand how to safely and efficiently utilize li-ion batteries, we must first have deep practical knowledge of thermal runaway.
You’ve probably seen stories in the news about electric vehicles catching on fire or product recalls for smartphones. Some of them have even resulted in people being harmed by fire, such as this example from Baseus power banks.
So, what exactly is thermal runaway, and how does it impact lithium-ion batteries?
Thermal runaway is a self-perpetuating process in which excessive heat within a battery triggers chemical reactions, leading to more heat.
This process typically starts with damage to the battery itself, either failure from within or external damage caused by misuse of the device in which it’s being used, or wear and tear without proper maintenance. When this happens, excessive heat starts building inside the battery pack.
This heat causes gas venting, a chemical reaction that increases the temperature and pressure of the battery.
If even a single cell within the battery back experiences enough heat and pressure, the entire li-ion battery pack could potentially catch fire or even explode. This chain reaction, called thermal propagation, is when neighboring cells ignite and it can be quite dangerous.
Understanding and preventing thermal runaway is crucial to address safety concerns in the many industries relying heavily on lithium-ion batteries.
There have been many examples of thermal runaway in recent years, which can be dangerous for the consumer and expensive for the company who makes the products.
For example, the Samsung Galaxy Note7 was recalled in 2016 because of a manufacturing defect in the phone's battery that caused it to overheat and catch fire. The phone was not designed to properly protect itself from thermal runaway and it was an expensive mistake.
In 2024, Chevron issued a recall for lithium-ion batteries, which were used in Skil power tools that were carried in Lowes, Walmart, and other retailers.
When these product recalls happen, the consequences can be devastating:
So, how can brands and manufacturers prevent thermal runaway and avoid the consequences of product recalls?
There are some high-quality advanced battery management systems (BMS) in the market that have properly designed battery packs with safe cell-to-cell spacing to include thermal management materials or cooling systems.
Other options include using fire-retardant materials in battery designs, practicing proper storage and charging habits of li-ion batteries, and avoiding physical damage or exposure to extreme temperatures.
We also offer solutions for thermal barriers and thermal regulation so that you can take care of all of your lithium-ion battery needs under one roof.
Contact us today to learn more about how our team of experts can support your product news from start to finish.