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<p>Large-format lithium-ion batteries are widely deployed in electric vehicles and energy-storage systems, but their increased capacity and energy density intensify the hazards associated with thermal runaway (TR). Although TR mechanisms have been extensively studied, systematic comparisons of high-capacity NCM and LFP batteries triggered by different abuse modes remain limited, particularly regarding gas generation behavior and explosion risks. In this study, TR characteristics of 200 Ah NCM and 230–280 Ah LFP cells were investigated under controlled overcharge and external heating conditions using a sealed 300&#xa0;L vessel that enabled simultaneous measurement of temperature evolution, internal pressure, mass loss, and vent-gas composition. Overcharge consistently induced more severe reactions than heating, producing higher peak temperatures and larger gas volumes. The NCM battery reached temperatures above 900&#xa0;°C and exhibited substantial mass loss (57–83%), whereas LFP batteries maintained structural integrity and lost only about 20% regardless of trigger mode. Gas generation analysis revealed that LFP cells produced 0.40–0.60&#xa0;L·Ah⁻<sup>1</sup>, while NCM cells generated 1.61–1.84&#xa0;L·Ah⁻<sup>1</sup>, reflecting more extensive electrolyte decomposition and oxygen-driven reactions in the layered NCM cathode. Gas composition differed markedly between chemistries: LFP cells released higher fractions of H₂ (42–52%), whereas NCM cells yielded more CO (24–38%), consistent with their distinct decomposition pathways. Despite these differences, the calculated explosion limits varied only slightly because major flammable gases, particularly H₂ and CO, remained within comparable aggregate ranges. These findings clarify the different TR behaviors of large-format NCM and LFP batteries and provide quantitative data essential for designing safer energy-storage systems, optimizing venting strategies, and developing protective measures to mitigate fire and explosion hazards in practical applications.</p>

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Trigger-mode-dependent thermal runaway behavior and combustion characteristics of large-format lithium-ion cells for energy-storage applications

  • 期刊论文

  • 发表日期：

    2026年4月6日

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  • Wentao Chen,
  • Biao Ma,
  • Xiaole Ma,
  • Shijie Zhang,
  • Chenglong Jiang,
  • Guangli Bai,
  • Fang Wang,
  • Shiqiang Liu

摘要

Large-format lithium-ion batteries are widely deployed in electric vehicles and energy-storage systems, but their increased capacity and energy density intensify the hazards associated with thermal runaway (TR). Although TR mechanisms have been extensively studied, systematic comparisons of high-capacity NCM and LFP batteries triggered by different abuse modes remain limited, particularly regarding gas generation behavior and explosion risks. In this study, TR characteristics of 200 Ah NCM and 230–280 Ah LFP cells were investigated under controlled overcharge and external heating conditions using a sealed 300 L vessel that enabled simultaneous measurement of temperature evolution, internal pressure, mass loss, and vent-gas composition. Overcharge consistently induced more severe reactions than heating, producing higher peak temperatures and larger gas volumes. The NCM battery reached temperatures above 900 °C and exhibited substantial mass loss (57–83%), whereas LFP batteries maintained structural integrity and lost only about 20% regardless of trigger mode. Gas generation analysis revealed that LFP cells produced 0.40–0.60 L·Ah⁻1, while NCM cells generated 1.61–1.84 L·Ah⁻1, reflecting more extensive electrolyte decomposition and oxygen-driven reactions in the layered NCM cathode. Gas composition differed markedly between chemistries: LFP cells released higher fractions of H₂ (42–52%), whereas NCM cells yielded more CO (24–38%), consistent with their distinct decomposition pathways. Despite these differences, the calculated explosion limits varied only slightly because major flammable gases, particularly H₂ and CO, remained within comparable aggregate ranges. These findings clarify the different TR behaviors of large-format NCM and LFP batteries and provide quantitative data essential for designing safer energy-storage systems, optimizing venting strategies, and developing protective measures to mitigate fire and explosion hazards in practical applications.