Lithium-ion Battery Thermal Safety by Early Internal Detection, Prediction and Prevention

Area of Science:

• Materials Science
• Electrochemistry
• Battery Technology

Background:

• Lithium-ion batteries (LIBs) face thermal runaway risks from internal temperature increases.
• Effective real-time monitoring of electrode temperature is crucial for preventing catastrophic battery failures.

Purpose of the Study:

• To develop and validate a customized LIB setup for early detection of internal temperature rise.
• To integrate an additive manufacturing-supported resistance temperature detector (RTD) for enhanced temperature monitoring.

Main Methods:

• An advanced RTD was embedded in a 3D-printed substrate within CR2032 coin cells, positioned behind the electrode current collector.
• The setup was tested under simulated thermal runaway conditions, comparing internal and external RTD measurements.
• A temperature prediction model was developed using internal and external RTD data.

Main Results:

• The internal RTD recorded temperatures 5.8°C higher than the external RTD.
• The internal RTD demonstrated a detection capability approximately 10 times faster than external monitoring.
• The system successfully prohibited thermal runaway events without impacting LIB operation.

Conclusions:

• The developed RTD system provides reliable, early detection of internal temperature rise in LIBs.
• Additive manufacturing enables robust sensor integration for harsh electrochemical environments.
• This technology enhances LIB safety by enabling proactive intervention against thermal runaway.