Comprehensive Insights on Techniques for Managing and Preventing Thermal Runaway in EV Lithium-Ion Batteries.

This paper presents a comprehensive investigation into the mechanisms, risks, and mitigation strategies associated with thermal runaway in lithium-ion batteries used in electric vehicles (EVs). It begins by emphasizing the urgency of the issue, identifying key vulnerabilities within EV battery systems that contribute to runaway events. A multiscale, stage-wise breakdown of thermal runaway progression is provided, illustrating how physical, chemical, and thermal interactions compound during failure scenarios. The study analyzes global incident data from 2000 to 2025, revealing trends in human health impacts, vehicle damage, and public safety concerns. Particular attention is given to how battery aging, manufacturing defects, and external abuse conditions elevate the likelihood and severity of thermal runaway. Current emergency response protocols and state-of-the-art mitigation technologies are critically evaluated to identify best practices and existing gaps in safety management. A hypothesis-driven investigation explores the distinct thermal runaway risks associated with compact battery formats, supported by simulated abuse and accelerated aging validation. The paper concludes by proposing advanced cooling strategies, improved battery chemistries, and safer architectural designs, aligned with evolving industry safety standards. By bridging scientific analysis with practical engineering and regulatory insight, this work offers high-impact, actionable solutions to support the development of safer, more resilient EV battery systems and to accelerate the transition toward sustainable electric mobility.