Learn about the risks, causes, and safety measures for lithium-ion battery fires. Discover preventative steps and solutions to avoid catastrophic battery fires.
We’re all tragically familiar with frequent news stories about the devastating effects of lithium-ion battery fires. Late in 2024, CBS reported a Bronx man's death due to a lithium-ion fire that occurred when he was charging the battery for his e-bike. The gentleman was charging the battery on the first floor when it sparked the fire, causing him to lose his life and severely harming other family members.
Another sensational headline was the New York Times reporting on the fire and explosion of a truck carrying lithium-ion batteries after a crash. No one was hurt in the incident, but seven miles of the highway were closed for 48 hours as the overturned truck remained on fire due to a thermal runaway event. The explosion caused the batteries being transported to erupt into flames as high as ten feet tall, leading to the chain reaction known as thermal runaway. The ignition of the batteries created the unstoppable chain reaction known as thermal runaway.
These dramatic incidents clearly illustrate the devastating impact lithium-ion battery fires can have; the worst-case scenario being the loss of life. Batteries can catch fire for several different reasons. Some of the common causes include:
Should the battery experiences one or more of these triggers the battery cells can burst and release hazardous gases, causing an intense fire.
Given the considerable number of potential triggers for lithium-ion battery fires and the significant risks when one occurs, tight safety measures are imperative to safeguard goods, infrastructure, and human life. This need for safety is especially true in e-mobility applications, where vehicles and people may be operating in remote areas, or subject to changing temperatures, pressures, and conditions at sea or in the air.
A range of safety measures must be used to mitigate the risk of fire. These measures should aim to prevent the occurrence of fire in the first place and mitigate the negative impact of a fire in the second place.
In the event of such preventative measures not being successful, fail-safe measures aimed at stopping or decreasing damage from thermal runaway should be the next line of defense.
For example, a gel polymer separator is a useful material, as it will melt and break down long before the battery’s temperature reaches the threshold for thermal runaway. However, the separator takes time to collapse and may not shut down the battery quickly enough. Flammable gases can still accumulate inside the battery, increasing pressure and temperature.
A venting mechanism can release the excess gas and heat in a controlled way rather than in an uncontrolled explosion. Solutions such as explosion panels and rupture discs are examples of venting mechanisms. They are the last line of defence as they do not prevent fires but can mitigate the worst effects and prevent catastrophic damage. They may vent fires directly to the atmosphere, however in many electric vehicles the batteries vent first into a ducting system.
OsecoElfab's OE Lion™ brand offers a range of specialist rupture discs designed for lithium-ion battery safety. The high-tech solutions are fully customizable to handle the unique and often challenging environments in which lithium-ion batteries operate in electric and hybrid vehicles. Whether it's the harsh conditions of sea travel, the fluctuating altitudes and temperatures in aircraft, or the compact spaces within electric vehicles, OE Lion offers a range of precision-engineered, custom solutions that ensure safety, reliability, and efficiency, even in the most demanding conditions.
With every disc, there is the option of adding a breather membrane for ongoing pressure equalization. Combining these two pressure safety features in a single device means both breathing and outgassing can be funneled though a single device, venting all gases from a common location. This improves your ability to control and disperse flammable vent gases. The result is a simpler, cleaner lithium-ion battery and enclosure design that is quicker to assemble and easier to integrate for safer, simpler and more cost-effective li-ion batteries.
Visit our product pages to view the full OE Lion range and learn more about our pressure safety solutions for eMobility.
To learn more about the options for protecting your lithium-ion cells and battery packs, contact our specialist lithium-ion engineering team today.