Now that we know why Li-ion batteries catch fire, let's look at some of the ways this can happen:
A. Manufacturing Defects
Defects in production can cause metal particles (impurities) to infiltrate lithium-ion batteries during the manufacturing process. Battery manufacturers need to ensure strict control over the cleanrooms used to manufacture batteries.
Another drawback could be the thinning of the separator, which can be detrimental in practical use. Batteries are subject to strict quality control testing and verification before being sold.
B. Design flaws
Car companies want to design their cars to be sleek and slim, while offering maximum range and performance. These requirements have prompted battery pack makers to come up with compact designs that pack high-capacity cells into smaller bodies, disrupting otherwise well-made cells.
Compromising the design may damage the electrodes or separator. Either of these could cause a short circuit. Additionally, the lack of a proper cooling system or vents can cause the battery temperature to rise as the flammable electrolyte heats up.
If left unchecked, it can cause a chain reaction of battery failure, causing the battery to heat up even more and get out of control.
C. Unusual or Improper Use
External factors such as bringing the battery very close to a heat source or near a fire source may cause the battery to explode. Deliberate or accidental puncturing of the battery pack is sure to result in a short circuit and battery fire. This is why unauthorized removal of an EV battery pack will void your warranty.
It is recommended that the user check and service the battery only from the vehicle manufacturer's authorized service center. Even high-voltage charging or over-discharging a battery can damage it.
D. Charger problem
Using a charger with poor insulation can damage the battery. If the charger shorts or heats up near the battery, enough damage could be done to cause it to malfunction.
While lithium-ion batteries have built-in protection against overcharging, using an unofficial charger can damage the battery in the long run.
E. Inferior components
In addition to manufacturing defects, the use of low-quality components is one of the top causes of battery failure. Rising competition is driving down battery prices, leading battery makers to cut corners where they shouldn't. By sparing inferior electronics such as battery management systems, the risk of battery failure increases.
The battery management system is critical to the safety and performance of the battery. It prevents the battery pack from operating outside its safe operating area. Since batteries are high-value components of electric vehicles or energy storage systems, it is imperative to invest in smart battery management systems to detect battery failures immediately and prevent battery explosions.
