A framework for modeling mechanically induced thermal runaway in lithium-ion batteries

Battery safety is a paramount concern in the development of electric vehicles (EVs), as failures can lead to catastrophic consequences, including fires and explosions. With the rapid global adoption of EVs, understanding how battery cells perform under extreme conditions such as mechanical or thermal abuse is crucial for ensuring vehicle safety. This study investigates the abuse response of lithium-ion batteries under high-speed mechanical loading. Our research systematically examines the response of these cells at different states of charge (SOC) through controlled dynamic tests. These tests offer insights into the failure response of the cells. By analyzing the data, we gain a deeper understanding of the conditions that could trigger thermal runaway under mechanical abuse loadings, representative of EV crashes, a critical safety concern in EV battery systems. The experimental setup and methodologies are presented in this paper, alongside key findings that highlight the importance of incorporating real-world conditions when evaluating cell safety. Following experimental results, a framework is presented to simulate cell behavior in thermal runaway, introducing the key phenomena that need to be considered in such modeling scenarios. These findings contribute to the development of more resilient battery systems, enhancing the overall safety of electric vehicles in real-world scenarios.