Internal Short Circuit Research Articles

Stable interphase inducer based on montmorillonite clay mineral to enhance stability and fire safety for lithium metal batteries

Heat buildup from factors like mechanical, electrical, or thermal stress is the main safety issue in lithium metal batteries (LMBs). Even without such stressors, however, LMBs may remain fire-prone because of the development of unstable electrode–electrolyte interphase on charge–discharge, potentially leading to internal short circuits. In this study, a stable cathode-electrolyte interphase inducer (SCEI-I) is proposed to tackle both the cycling stability issue and safety concerns. SCEI-I is synthesized by incorporating montmorillonite, a clay mineral, and methylphosphonic acid dimethyl ester, a flame-retardant material, onto a porous polyethylene film. On cycling, SCEI-I can induce a thin (<8 nm), uniform and robust cathode-electrolyte interphase layer, contributing to a steady and high Coulombic efficiency of 99.6%–99.8% with decreased impedance. SCE-I improves electrochemical performance by reducing the capacity degradation from ∼21.9% to ∼8.9% after 100 cycles. SCE-I also demonstrates strong thermal stability as the endothermic energy of SCEI-I is only –32.4 J/g (24 °C–280 °C), which is less than one-third of that of polypropylene separator (–118.9 J/g). Furthermore, when exposed to fire, the SCEI-I membrane instantly extinguished flames by disrupting combustion chain reaction. The present study proposes an interfacial engineering approach to improve the stability and safety of LMBs.

Impact of an interrupted mechanical deformation on the electrical behavior of commercial lithium-ion pouch cells with varied aging histories for battery qualification

This study investigates the influence of non-critical mechanical deformations, i.e., without internal short circuit (ISC), on lithium-ion batteries and examines their correlation with changes in electrical parameters. Nine commercial 50 Ah NMC111/Graphite pouch cells with diverse aging histories were electrochemically cycled before and after a controlled mechanical deformation. The results revealed consistent alterations in electrical parameters after deformation, including state of health (SOH) upon discharging, Coulombic efficiency, constant current discharge time (CCDT), voltage relaxation profile (VRP) voltage, VRP slope, and Area VdQ. Morphological changes due to deformation affected the overall electrical cell behavior. The deformation-induced effects are attributed to electrolyte shifting and electrode cracking which leads to loss of active material (LAM), whereas the morphological changes directly contributed to increased internal resistance (IRI) and an increase in the heterogeneity of the current distribution over the electrode surface. Distinct effects were observed in different-aged cells, with non-electrically aged cells being more affected by the electrode cracking and the current imbalances increase. The study underscores the high importance of early detection of non-critical mechanical deformations for ensuring battery safety and makes valuable contributions to battery qualification and the assessment of second-life batteries.

Adaptive fault detection for lithium-ion battery combining physical model-based observer and BiLSTMNN learning approach

Lithium-ion batteries possess one of the best energy-weight ratios, while safety and reliability are critical issues for its continued operation. Due to extreme fast-charging, huge application sizes and variable usage environment, the risk of soft battery faults, including soft internal short circuit (SISC), is increased and may evolve into severe accidents. Therefore, accurate early detection of lithium-ion battery fault is imperative to guarantee the battery performance. Motivated by this fact, we proposed a real time fault detection framework for battery soft faults. Based on the Equivalent Circuit Model (ECM) and coupling thermal model, Extended Kalman Filter (EKF) observer is used for reliable monitoring of battery voltage and surface temperature. Inspired by uncertainty interference during the observation process, we explore an observed-based learning approach that combine physical model-based observer and Bidirectional Long Short-Term Memory neural networks (BiLSTMNN) to empower the observer with the ability to learn the uncertainties, which is efficient in distinguishing soft faults information and uncertainties from residual. Furthermore, the memory characteristics of BiLSTMNN are considered to improve the robustness of the detection system, including comprehensive training data and optimized input features. Finally, through the comparative analysis and the robustness evaluation experiments including various driving cycles and internal short circuits (ISC) faults test verity the good performance of the proposed method.

Three-dimensional electrochemical-magnetic-thermal coupling model for lithium-ion batteries and its application in battery health monitoring and fault diagnosis

Storage batteries with elevated energy density, superior safety and economic costs continues to escalate. Batteries can pose safety hazards due to internal short circuits, open circuits and other malfunctions during usage, hence real-time surveillance and error diagnosis of the battery’s operational state is imperative. In this paper, a three-dimensional model of electrochemical-magnetic field-thermal coupling is formulated with lithium-ion pouch cells as the research focus, and the spatial distribution pattern of the physical field such as magnetic field and temperature when the battery is operational is acquired. Furthermore, this manuscript also investigates the diagnostic methodology for defective batteries with internal short circuits and fissures, that is, the operational state of the battery is evaluated and diagnosed by the distribution of the magnetic field surrounding the battery. To substantiate the method’s practical viability, the present study extends its examination to the 18650-battery pack. We obtained the magnetic field images of the normal operation of the battery pack and the failure state of some batteries and analyzed the relationship between the magnetic field distribution characteristics and the performance of the battery pack, providing a new method for the health monitoring and fault diagnosis of the battery pack. This non-contact method incurs no damage to the battery, concurrently exhibiting elevated sensitivity and extremely rapid response time. Meanwhile, it provides an effective means for non-destructive research on the batteries and can be applied to areas such as battery safety screening and non-destructive testing. This research not only helps to facilitate our understanding of the battery’s operating mechanism, but also provides robust support for safe operation and optimal battery design.

Rate-dependent damage and failure behavior of lithium-ion battery electrodes

The mechanical properties and failure behavior of composite electrodes are critical to understanding the internal short circuits and ensuring the crush safety of lithium-ion batteries used in electric transportation. This study provides a comprehensive experimental investigation into the strain rate–dependent tensile/compressive behavior and failure mechanism of both anode and cathode, covering a range from quasi-static to dynamic conditions. A universal testing machine equipped with an industrial camera was used to assess the mechanical properties and observe the deformation process of the electrodes under quasi-static conditions. Additionally, a split Hopkinson bar system, coupled with a high-speed camera, was utilized to evaluate the mechanical properties and capture the deformation process of the electrodes under dynamic loading. The detailed deformation and failure modes of the electrodes were revealed by a combination of post-mortem characterization and images from high-speed cameras. The experimental results demonstrate a significant strain rate effect on the tensile and compressive mechanical behavior and failure mechanism of both anode and cathode. The rate dependence of tensile/compressive strength and failure strain were discussed, and the underlying mechanism for strain rate sensitivity was analyzed. The results and conclusions from this study provide an important foundation for the detailed modeling and failure prediction of lithium-ion batteries under impact loading. Further, these findings facilitate the safety design of electric vehicles by informing to enhance crash safety.

Co@CoO core–shell cross-linked framework modified 3D Cu for dendrite-free lithium anode

Lithium metal anode with high energy density is important for developing next-generation batteries. However, low coulombic efficiency, short cycle life, internal short circuits caused by the growth of lithium dendrites, and the high reactivity with the electrolyte have seriously hindered the practical application of lithium metal anode. Herein, we constructed a core–shell cross-link matrix on copper, Co@CoO/3D Cu, for Li metal anode optimization. Various characterizations and DFT simulations jointly reveal the great effects of the special structural features of Co@CoO/3D Cu on enhancing the coulombic efficiency and cyclic stability of Li metal anodes. As a result, the modified half-cell could cycle stably for 240 cycles at 1 mA cm−2 and 1 mA h cm−2 with a coulombic efficiency as high as 98 %. The modified symmetric cell could cycle stably for 1400 h at 1 mA cm−2 and 1 mA h cm−2 with a very low polarization of 22 mV. The modification method proposed in this paper provides a novel path for Li metal anode optimizations.

Voltage-fault diagnosis for battery pack in electric vehicles using mutual information

The safety of battery system is compromised by the abusive operation and aging, potentially resulting in the abnormal voltage levels. Rapid detection and accurate diagnosis of voltage fault are crucial for ensuring the safety of battery packs. A battery voltage fault diagnosis method is proposed by using the mutual information in this work, which can identify faulty cells timely. Specifically, the voltage of battery pack in an electric vehicle is collected, and the mutual information of voltages between each paired-cells is calculated. The presence of faulty cells disturbs the original distribution of mutual information. Therefore, the Ryan Joiner (RJ) test is used to judge whether the normal distribution of calculated mutual information or not. The interquartile test is used to detect the outliers. The faulty cell is diagnosed by matching the cell corresponding to the outliers. The defaults resulting from an internal short circuit and mechanical vibration are analyzed and diagnosed. The method can avoid misdiagnosis caused by the mutual influence between different faults. Furthermore, the fault diagnosis capability of presented method is discussed under various states of aged cells. The experimental results verify the effectiveness, robustness, model-free, and easiest-to-implement of the presented method.

Early-Stage ISC Fault Detection for Ship Lithium Batteries Based on Voltage Variance Analysis

With the progressive development of new energy technologies, high-power lithium batteries have been widely used in ship power systems due to their high-power density and low environmental pollution, and they have gradually become one of their main propulsion energy sources. However, the large-scale deployment of lithium batteries has also brought a series of safety problems to ship operations, especially the battery internal short circuit (ISC). Battery ISC faults are very hidden and unpredictable at the initial stage and often fail to be detected in time, ultimately leading to overheating, fire or even an explosion of the ship’s power system. Based on this, this paper proposes a fast and accurate method for early-stage ISC fault location and detection of lithium batteries. Initially, voltage variations across the lithium battery packs are quantified using curvilinear Manhattan distances to pinpoint faulty battery units. Subsequently, the localized characteristics of voltage variance among adjacent batteries are leveraged to detect an early-stage ISC fault. Simulation results indicate that the proposed method can quickly and accurately locate the position of 5 Ω, 10 Ω and 15 Ω ISC faulty batteries within the battery pack, as well as detect the abnormal batteries in a timely manner with considerable sensitivity and reliability.

Experimental study on the internal short circuit and failure mechanism of lithium-ion batteries under mechanical abuse conditions

The safety issues of lithium-ion batteries under mechanical abuse conditions have attracted widespread attention due to their high uncertainty and risk. This research takes cylindrical lithium-ion batteries as the research object and conducts three-point bending tests on cylindrical lithium-ion batteries with different states of charge (SOC), electrode thicknesses and electrode materials. The mechanical response, voltage changes, temperature changes during the loading process of the battery, and the microstructural changes of the battery's electrodes and separator after the bending test were examined. The results show that the maximum load-bearing capacity of the battery and the displacement corresponding to the short circuit decreases with the SOC of battery; the higher the battery SOC means a faster average temperature rise rate of the battery. When the SOC is higher than 60 %, the battery will experience violent thermal runaway phenomena such as explosions and spouting fire after bending tests. The mass loss rate of the battery is also greatly affected by the battery SOC and the electrode thickness, however, electrode material have almost no effect on the mass loss rate of the battery. According to the SEM images of the electrodes, it is found that short circuits cause graphite particles to break, separators to close and electrolytes oxidize on the surface of positive electrode particles. After triggering the internal short circuit, more broken particles are observed in the positive electrode material of the battery with thicker electrodes and the surface roughness of the broken particles is higher. By comparing the electrode changes of LFP and NCM, it is found that the intensity of the internal electrochemical reactions in NCM is far greater than that in LFP. The research results provide theoretical insights for understanding the electrothermal characteristics and mechanical integrity of lithium-ion batteries under mechanical abuse, which can shed light on the design and optimization of high-performance and safe lithium-ion batteries.

Ultrasonic assessment of aging in lithium metal pouch cells

Lithium metal anodes are prone to non-uniform lithium plating that can lead to dendrite formation, internal short circuits, and catastrophic ignition. This type of structural defect is not captured by battery management systems, prompting the need to advance nondestructive evaluation (NDE) techniques that are suitable for periodic monitoring of the internal structure. An ultrasonic inspection technique is evaluated here as a means of identifying flaws and irregular lithium plating that can be a precursor to dendrite formation and, ultimately, battery failure.Lithium metal pouch cell batteries were aged through electrochemical cycling at a range of moderate constant-current charging and discharging rates. They were inspected intermittently using a tailored local ultrasonic resonance spectroscopy (LURS) approach that measures the local through-thickness resonances of the battery as an indicator of the underlying structure. LURS results showed clear structural resonances in cells in the range of 3–7 MHz, which shifted significantly to lower frequencies as batteries aged. In addition to point measurements, scanning LURS measurements were implemented to map resonance frequencies over the electrode surface. These resonance maps revealed spatial variations in structure that developed during aging and showed better contrast to structural variation than achieved using conventional amplitude-based c-scans of the specimens.NDE results from pouch cell measurements were compared to a destructive physical analysis of the electrode structures using scanning electron microscopy (SEM). The SEM results showed differences in the end-of-life lithium anode structure at different charge rates. The results of this study show the capability of LURS as a means for identifying changes in battery structures during aging and establish resonance trends that may be applied in future work for prognostic modeling of batteries in service.

Asymmetric ionogel electrolyte with an ultrathin metal–organic framework layer for lithium dendrite inhibition in solid-state lithium-metal batteries

Solid-state electrolytes (SSEs) are used to prevent internal short circuits caused by the growth of lithium dendrites in solid-state lithium-metal batteries (SSLMBs). Ionogel electrolytes are new polymeric SSEs with outstanding processability, excellent flexibility, and superior ionic conductivity. Lithium-ion transport in ionogel electrolytes depends on ionic liquid (IL) content; however, increasing the IL content improves ionic conductivity but sharply decreases mechanical properties, thus limiting the ability to resist lithium dendrites. Thus, ionogel electrolytes must strike a balance between ionic conductivity and mechanical properties. Herein, we adopt a new strategy to suppress the growth of lithium dendrites by in situ polymerizing an ultrathin metal–organic framework (MOF) layer (9.8 μm) onto a highly ionic conductive ionogel electrolyte. The ionogel electrolyte provides an asymmetric SSE (ASSE) with a remarkable ionic conductivity of 4.8 × 10−4 S cm−1 (30 °C), whereas the ultrathin MOF layer regulates uniform dissolution/deposition of lithium and inhibits lithium dendrite growth, thereby increasing critical current density of the ASSE to 0.65 mA cm−2. An SSLMB assembled with the ASSE and LiFePO4 exhibits excellent performance and cycling stability, maintaining a specific capacity of 125.4 mAh g−1 after 500 cycles at 0.3C.

An integrated cell-to-pack design based on an origami sandwich structure to enhance cooling and mechanical performances of battery packs in electric vehicles

The rapid growth in the energy density of batteries in electric vehicles has led to the need for complex structural components and cooling systems to ensure the safety of the battery pack. However, these inactive materials occupy a significant portion, accounting for at least 35% of the pack's volume. To enhance the volume utilization rate of the battery pack, this paper proposes a novel origami structure with its optimized geometry that enhances thermal and mechanical performances as well as crashworthiness performance. The simulation results of temperature evaluation show that the proposed origami channels for a battery pack can reduce the maximum temperature by more than 2.6 °C at a 5C discharging rate and by over 20 °C under internal short-circuit conditions compared with a flat cooling channel. The experimental results of a quasi-static punch compression test demonstrate the enhanced mechanical properties of the origami channels with a significant increase in peak crushing force and impact energy absorption compared with flat cooling channels.

Experimental analysis and safety assessment of thermal runaway behavior in lithium iron phosphate batteries under mechanical abuse

Mechanical abuse can lead to internal short circuits and thermal runaway in lithium-ion batteries, causing severe harm. Therefore, this paper systematically investigates the thermal runaway behavior and safety assessment of lithium iron phosphate (LFP) batteries under mechanical abuse through experimental research. Mechanical abuse experiments are conducted under different conditions and battery state of charge (SOC), capturing force, voltage, and temperature responses during failure. Subsequently, characteristic parameters of thermal runaway behavior are extracted. Further, mechanical abuse conditions are quantified, and the relationship between experimental conditions and battery characteristic parameters is analyzed. Finally, regression models for battery safety boundaries and the degree of thermal runaway risk are established. The research results indicate that the extracted characteristic parameters effectively reflect internal short circuit (ISC) and thermal runaway behaviors, and the regression models provide a robust description of the battery's safety boundaries and thermal runaway risk degree. This work sheds light on understanding thermal runaway behavior and safety assessment methods for lithium-ion cells under mechanical abuse.

METHODOLOGY FOR EXPERIMENTAL RESEARCH OF THE FIRE HAZARD OF POWER LITHIUM-ION BATTERIES OF ELECTRIC VEHICLES UNDER THE INFLUENCE OF A HEATING PANEL

Even though lithium-ion batteries (LIBs) are the subject of various tests and research at the production stage, there are no isolated cases of electric vehicle fires, and the development dynamics are unpredictable. The particular danger of such fires lies in the oxygen release during an irreversible exothermic reaction in LIBs, which creates new challenges for fire and rescue services when extinguishing such fires. The study aims to develop the main provisions of the methodology for experimental studies of electric vehicle power batteries in terms of fire hazards using an electric heating panel. The ultimate goal of the study is to determine the temperatures at which an irreversible exothermic reaction, the opening of ventilation holes, and the combustion (explosion) of electric vehicle power batteries begin, as well as the time parameters at which such processes occur. Taking into account the peculiarities of the occurrence and course of the irreversible exothermic reaction, we have developed a methodology, the essence of which is to determine the temperatures of the onset of the irreversible exothermic reaction of the electric vehicle power battery, the opening of ventilation holes, and the combustion (explosion) of electric vehicle power batteries, the combustion temperatures of ventilation gases, as well as the time parameters at which these processes occur, which may change during battery operation and not correspond to the declared parameters of the manufacturer. For this purpose, we exposed LIBs to thermal energy from an electric heating panel and recorded the temperature and time during which an irreversible exothermic reaction occurs from the moment of an internal short circuit to a fire or explosion. The use of the proposed methodology of experimental studies of the elements of power batteries of electric vehicles regarding the fire hazard of an electric heating panel will make it possible to determine the temperature limits of the occurrence of irreversible exothermic reactions in LIBs, as well as the time parameters under which these processes occur. Keywords: electric vehicle fire, irreversible exothermic reaction, lithium-ion battery.

Effects of Trigger Method on Fire Propagation during the Thermal Runaway Process in Li-ion Batteries

Abstract Lithium-ion batteries are prone to fire hazards due to the possibility of thermal runaway propagation. During battery product development and subsequent safety tests for design validation and safety certification, the thermal runaway onset is triggered by various test methods such as nail penetration, thermal ramp, or external short circuit. This failure initiation method affects the amount of heat contributions and the composition of gas generations. This study compares two such trigger methods, external heating and using a thermally-activated internal short circuit device (ISCD). The effects of the trigger method on total heat generation are experimentally investigated within 18650 cylindrical cells at single cell level as well as at multiple cell configuration level. The severity of failure was observed to be worse for cells with ISCDs at single cell level, whereas quite the opposite results were observed at multiple cell configuration level. A preliminary numerical analysis was performed to better understand the battery safety performance with respect to thermal runaway trigger methods and heat transfer conditions.

Numerical study on the critical characteristics of internal short-circuit hot spot in lithium-ion batteries

High current density resulting from internal short circuit (ISC) in lithium-ion batteries leads to rapid local temperature rise, forming a hot spot. This study quantitatively characterized the critical properties of ISC hot spot in batteries. ISC hot spot in batteries exhibit two different evolution patterns. When the short circuit resistance approaches the internal resistance of the battery, the hot spot temperature reaches its peak at 1165 K. The thermal runaway characteristics of batteries vary depending on the short circuit resistance, with the hot spot growing and spreading rapidly when the resistance value is 30 mΩ. In addition, a modeling study was conducted to examine the critical characteristics of short circuit resistance. At a hot spot radius of 2 mm, the critical resistance was determined to be 281 mΩ, accompanied by a critical hot spot temperature of 562 K. Under subcritical conditions, the SEI film decomposes completely, while the electrolyte undergoes minimal decomposition. Interestingly, it was observed that the critical resistance and critical hot spot temperature decrease as the hot spot radius increases. Finally, the study quantified the effects of hot spot thermal conductivity, convective heat transfer coefficient, and hot spot position on the critical threshold of hot spots. These findings provide valuable references for the design of batteries with high critical thresholds.

Comparative Study on the Electrochemical Behaviors of Positive Electrode Materials of Lithium-ion Batteries during Overdischarge

As lithium-ion battery (LIB) use rises, recycling becomes imperative. Efficiently overdischarging LIBs for residual energy extraction is crucial for safe recycling. Our study analyzes the electrochemical behavior during overdischarge for positive electrode materials, including LiNi0.6Co0.2Mn0.2O2 (NCM622), LiNi0.8Co0.1Mn0.1O2 (NCM811), LiFePO4 (LFP), LiCoO2 (LCO), and LiMn2O4 (LMO). Electrochemical evaluations involve half cells and full cells subjected to constant current overdischarge beyond normal operating ranges. In positive electrode half-cells, a material-dependent conversion reaction was observed, while full cells exhibited similar behaviors during overdischarge to 0 V due to increasing voltage at the negative electrode. Distinct electrochemical variations emerged under forced discharge below 0 V, particularly in the NCM series, showing a gradual voltage decrease to −2 V followed by an internal short circuit. In contrast, LFP, LCO, and LMO swiftly stabilized near 0 V, attributed to the lower initial Coulombic efficiency of NCM materials leading to an early rise in negative electrode potential. To recycle used lithium-ion batteries (LIBs), it’s crucial to optimize conditions that ensure both efficient and safe overdischarge, considering the characteristics of positive electrode materials.

Data-Driven Fault Diagnosis of Internal Short Circuit for Series-Connected Battery Packs Using Partial Voltage Curves

Data-Driven Fault Diagnosis of Internal Short Circuit for Series-Connected Battery Packs Using Partial Voltage Curves

Experimental study on behaviors of lithium-ion cells experiencing internal short circuit and thermal runaway under nail penetration abuse condition

This work compared the macro-phenomenon, voltage response, surface temperature, mass loss and material characteristics of LiCoO2 (LCO), LiMn2O4 (LMO), Li(NixCoyMnz)O2 (NCM), LiFePO4 (LFP) cells with the same capacity under penetration tests. The tests provided an in-depth study on behaviors and properties of internal short circuit (ISC) and thermal runaway (TR). From the results, a feature was discovered that the parameters of different types of cells showed different tendencies when penetrated with a series of diameter nails, determined by cathode materials. The LFP cell experienced a slight ISC. Temperature rise rate and maximum temperature increased with larger diameter of nails. The NCM, LCO and LMO cells experienced a severe ISC. The maximum temperature of cells increased, however, the temperature rise rate reduced and macro-phenomena delayed and weakened with larger diameter of nails. For different type of cells, the order of ISC sensitivity was as follows: LCO > LMO > NCM > LFP. As state of charge (SOC) increased, the cells had a higher risk of TR, evidenced by higher surge current and temperature rise rate. The results of nail penetration tests at 100 % SOC indicated that the hazard of TR was arranged in the order of LCO > NCM > LMO > LFP. Due to the fragmentation of secondary particles during the extrusion of nail, the cathode composed of secondary particles suffered more damage than composed of primary particles. The research can provide support for the safety design of cells.

IDENTIFYING THE ROLE OF ELECTROLYTE ADDITIVES FOR LITHIUM PLATING ON GRAPHITE ELECTRODE BY OPERANDO X‐RAY TOMOGRAPHY

The plating of lithium on the graphite electrode is a major degradation mechanism in lithium‐ion batteries (LIBs) and brings safety concerns and leads to short cycle life. Understanding how and when plating occurs is crucial for the development of mitigation strategies, e.g. tuning the electrolyte composition. We present an operando X‐ray tomographic microscopy study to monitor the plating of lithium on a graphite electrode. XTM enables non‐destructive, quantitative operando characterization of lithium deposition and allows us to probe the role of the electrolyte additives vinylene carbonate and lithium bis(fluorosulfonyl)imide in the standard electrolyte LP57. The additives show a better performances in terms of delayed onset of lithium plating, important to utilise the full capacity of the graphite, since once lithium plating is initiated this rapidly becomes dominating and hinders further intercalation. For the base electrolyte a homogeneous and dense morphology of plated lithium is found, whereas a more dendritic morphology is observed in the presence of additives. During delithiation, there is a rapid stripping of some of the plated lithium followed by deintercalation. In addition, our work provides a general methodology to track the morphology of plated lithium, which is crucial for fundamental research about battery safety.