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<p>As the battery pack becomes more compact, it also raises concerns about safety issues. The high temperature jet fire of thermal runaway (TR) will be able to distort and damage the up-cover baffle of battery pack. However, research into the interaction between TR jets and upper cover plates is currently lacking, particularly with regard to measuring impact forces and temperatures. In this study, the TR experiments are performed and equipped with an up-cover baffle located above the safety valve. Considering the variables of LiNi<sub>0.7</sub>Co<sub>0.1</sub>Mn<sub>0.2</sub>O<sub>2</sub> and LiNi<sub>0.5</sub>Co<sub>0.2</sub>Mn<sub>0.3</sub>O<sub>2</sub> of cathode materials, gap distances, and states of charge (SOC), the impingement force and impact temperature to the baffle are investigated. Further, in order to link the impingement force with the internal TR mechanism, an estimation of internal temperature is proposed. The maximum impingement force is 15.06&#xa0;N, and the maximum center temperature of baffle is 597.3 ℃ at 100% SOC for LiNi<sub>0.7</sub>Co<sub>0.1</sub>Mn<sub>0.2</sub>O<sub>2</sub> battery with 2&#xa0;cm gap. The impact temperature can significantly compromise the baffle’s strength. The interplay of these factors can culminate in the failure of the up-cover baffle. Furthermore, the impact force responds more rapidly than the surface temperature, and can serve as a sensitive indicator for TR monitoring. This study demonstrates that the pursuit of more compact and higher energy-density battery pack designs inevitably entails greater risk.</p>

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Measurements of Thermal Runaway Impingement Forces and Temperature Aagainst Baffles in Prismatic Lithium-Ion Battery Packs

  • 期刊论文

  • 发表日期：

    2026年6月23日

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  • Peng Gao,
  • Junyuan Li,
  • Zhuangzhuang Jia,
  • Zhixiang Cheng,
  • Bang Tong,
  • Mingwei Cao,
  • Wenxin Mei,
  • Peng Qin,
  • Jinhua Sun,
  • Kaiqiang Jin,
  • Qingsong Wang

摘要

As the battery pack becomes more compact, it also raises concerns about safety issues. The high temperature jet fire of thermal runaway (TR) will be able to distort and damage the up-cover baffle of battery pack. However, research into the interaction between TR jets and upper cover plates is currently lacking, particularly with regard to measuring impact forces and temperatures. In this study, the TR experiments are performed and equipped with an up-cover baffle located above the safety valve. Considering the variables of LiNi0.7Co0.1Mn0.2O2 and LiNi0.5Co0.2Mn0.3O2 of cathode materials, gap distances, and states of charge (SOC), the impingement force and impact temperature to the baffle are investigated. Further, in order to link the impingement force with the internal TR mechanism, an estimation of internal temperature is proposed. The maximum impingement force is 15.06 N, and the maximum center temperature of baffle is 597.3 ℃ at 100% SOC for LiNi0.7Co0.1Mn0.2O2 battery with 2 cm gap. The impact temperature can significantly compromise the baffle’s strength. The interplay of these factors can culminate in the failure of the up-cover baffle. Furthermore, the impact force responds more rapidly than the surface temperature, and can serve as a sensitive indicator for TR monitoring. This study demonstrates that the pursuit of more compact and higher energy-density battery pack designs inevitably entails greater risk.