Solid-state lithium-ion batteries offer a promising solution for electric vehicle energy storage by replacing flammable liquid organic electrolytes with non-flammable solid alternatives, thus significantly enhancing safety levels.1 However, despite this potential, the safety of these batteries remains a subject of debate due to a lack of quantified understanding, and existing standards may not adequately address anticipated failure modes. Consequently, there is a pressing need to characterize and quantify the safety of solid-state cells, considering the unique chemistry of each component. Although solid electrolytes aim to reduce the instances of soft shorts between electrode, one of the major safety concerns in solid-state batteries is the occurrence of internal short circuits (ISCs) under faliure circumstance, which pose significant challenges in terms of durability and safety, particularly in automotive applications. ISCs can lead to rapid and catastrophic discharge of up to 70% of the total cell energy in under 60 seconds, resulting in substantial self-heating and potentially initiating thermal runaway.2 To evaluate the safety of solid-state cells, abuse testing has become a standard practice, involving techniques such as nail penetration, crush testing, accelerating rate calorimetry, and overcharging. These tests expedite ISC occurrences, enabling researchers to gain insights into cell behaviour under extreme conditions and facilitating safety assessments. In this study, we conducted a comprehensive examination by subjecting commercial solid-state cells and Li-ion cells of similar energy to catastrophic failure conditions. In conducting this work, we aim to provide a comparative analysis of the challenges encountered by solid-state cells and to quantify the impact of scale-up on safety and failure events, ranging from cell capacities of 2 Ah to 10’s of Ah, and examining the propagation of failure through battery packs. To achieve this, we utilized a diverse array of abuse testing and characterization techniques, including X-ray CT, SEM, and GCMS. Through this endeavour, we aim to establish a benchmark for solid-state failure analysis and quantification, contributing to the advancement of safer battery technologies.[1] Mauro Pasta et al 2020 J. Phys. Energy 2 032008[2] Hossein Maleki and Jason N. Howard 2009 J. Power Sources. 2 568-574
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