SETsafe | SETfuse Solutions for Lithium Battery Thermal Runaway Safety Protection

PROTECT WITH "CHIP," SECURE WITH "CHIP"

For the Technical Article on lithium battery thermal runaway safety protection Solutions: "Safety Device" - SETsafe | SETfuse solution products.

Product 1

Cell Overheat Breaker (COB)

All Newly Designed

Key Features:

Temperature-Sensitive Element.

Operating Temperature Range of 72–230°C With an Accuracy Of ±2°C.

High Instantaneous Current Tolerance: Meets 15ir@3ms Surge Current Requirements.

Low Internal Resistance, Low Power Consumption: Enhances Battery Efficiency.

Integrated, Flat Design: Facilitates Easy Integration Into Battery Modules.

Single-Use, Non-Resettable Action: Ensures Reliable Circuit Disconnection During Anomalies.

Environmental Compliance: Meets RoHS and REACH.

Application: Designed For 18650 Cylindrical Cells.

Customizable: Tailored Solutions Available To Meet Specific Requirements.

Product 2

Thermal-Link Alloy Type (ATCO)

Newly Designed YF Series for Cell Thermal Runaway Protection

Key Features:

Temperature-Sensitive Element: Compact Design With an Operating Temperature Accuracy of ±2°C.

Single-Use, Non-Resettable Action: Provides Dependable Over-Temperature Protection.

Environmental Compliance: Meets RoHS and REACH.

Customizable: Adjustable Parameters To Suit Specific Applications.

Applications

Suitable for Pouch Cells and Cylindrical Cells.

Operating Principle

The failure mode of lithium batteries often manifests as abnormal heat generation. SETsafe | SETfuse solutions utilize low-melting-point alloys as protective electrical connections. In the event of a single anomaly, the alloy melts, rapidly disconnecting the thermal and electrical pathways with the aid of a fluxing agent. This thermo-electrical separation minimizes the likelihood of thermal propagation, enhancing overall battery safety.

For more information, please contact: sales@SETfuse.com

Technical Article

SETsafe | SETfuse Solutions for Lithium Battery Thermal Runaway Safety Protection (For Reference Only)

Causes of Lithium Battery Thermal Runaway

Thermal runaway in lithium batteries refers to a rapid temperature increase under certain abnormal conditions, triggering uncontrollable chemical reactions that may lead to combustion or explosion. Key Causes Include:  

Overcharging / Over-Discharging: 

Exceeding safe voltage ranges leads to electrolyte decomposition, gas generation, or electrode material degradation. 

Short Circuits: 

Internal short circuits (e.g., manufacturing defects, separator damage) or external short circuits (e.g., wiring faults) cause high currents and localized overheating. 

High-Temperature Environments: 

External heat sources (e.g., fire, prolonged sun exposure) or poor heat dissipation push battery temperatures beyond critical thresholds. 

Mechanical Damage: 

Impacts, crushing, or punctures compromise internal structures, leading to short circuits or electrolyte leakage. 

Manufacturing Defects:

Impurities in electrode materials, separator flaws, or improper assembly increase thermal runaway risks. 

Battery Aging: 

Material degradation from repeated cycling increases side reactions, potentially triggering thermal runaway.

Phenomena 

Phenomena of Thermal RunawayThe thermal runaway process is typically accompanied by the following:  

Rapid Temperature Increase: Battery temperatures can rise to hundreds of degrees Celsius. 

Gas Release: 

Electrolyte decomposition generates flammable gases (e.g., H₂, CO, CH₄), causing cell swelling or venting. 

Smoke and Flames: 

Cell casing rupture releases toxic fumes, potentially leading to combustion or explosion. 

Electrical Anomalies: 

Voltage fluctuations and rapid capacity loss. 

Physical Deformation: 

Cell swelling, rupture, or electrolyte leakage.

Solutions 

Solutions Preventing and mitigating thermal runaway requires a multi-faceted approach, encompassing design, manufacturing, usage, and emergency management.

Enhanced Battery Design: 

Material Optimization: 

Use high-thermal-stability cathode materials (e.g., lithium iron phosphate [LFP] instead of nickel-cobalt-manganese [NCM]), high-temperature-resistant electrolytes, and ceramic-coated separators. 

Safety Devices: 

Incorporate explosion-proof valves, thermistors, or over-temperature fuses to release pressure or interrupt current flow promptly. 

Thermal Management:

Implement efficient battery management systems (BMS) with liquid or air cooling to regulate temperatures.

Manufacturing Quality Control:

Enhance production process consistency to minimize impurities and defects. 

Rigorously screen and test individual cells to eliminate internal short-circuit risks.

Battery Management System (BMS) Optimization: 

Real-time monitoring of voltage, current, and temperature to detect anomalies promptly. 

Implement overcharge, over-discharge, and over-temperature protection mechanisms to automatically disconnect circuits. 

Integrate AI algorithms to predict thermal runaway risks.

ConclusionLithium battery thermal runaway results from a complex interplay of factors across design, manufacturing, and usage. By optimizing materials, enhancing BMS capabilities, standardizing usage protocols, and implementing robust emergency measures, thermal runaway risks can be significantly reduced.  SETsafe | SETfuse’s COB and ATCO solutions provide precise, reliable, and customizable thermal protection, ensuring core safety for lithium battery applications.