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<p>Nowadays, Ni-rich mixed transition-metal cathode materials are extensively investigated for lithium-ion batteries (LIBs) in electric vehicles (EVs) because of their high operating voltage, superior specific capacity, and enhanced energy density. However, their practical application remains limited by structural instability, thermal safety issues, and insufficient early-warning systems against thermal runaway. By this work a combination of {[(1–x–y) LiNi<sub>0.333</sub>Mg<sub>0.333</sub>Mn<sub>0.333</sub>] O<sub>2</sub>}, xLi<sub>2</sub>MnO<sub>3</sub>, yLiCoO<sub>2</sub> composite systems were synthesized using the sol–gel method. Proper stoichiometric weights of the LiNO<sub>3</sub>, Mg (NO<sub>3</sub>)<sub>2</sub> ⋅ 6H<sub>2</sub>O, Mn (Ac)<sub>2</sub> ∙4H<sub>2</sub>O, Co(Ac)<sub>2</sub>⋅ 4H<sub>2</sub>O, Ni(NO<sub>3</sub>)<sub>2</sub>⋅6H<sub>2</sub>O as starting materials of lithium, magnesium, Manganese, cobalt and nickel, in 28 samples of the system, respectively were determined. To improve LIB safety, a multifunctional temperature–resistance monitoring system integrated with resistive room-temperature H<sub>2</sub> sensor and equivalent circuit model–fault detection and isolation (ECM–FDI) diagnostics was designed and fabricated. The proposed sensor enabled early detection of lithium dendrite growth through hydrogen evolution prior to smoke generation and thermal runaway. Quantitative analysis showed a minimum detectable dendrite mass of approximately 2.75 × 10<sup>−4</sup>&#xa0;mg, providing an effective early-warning window for EV battery protection. Post-cycling SEM and XRD analyses confirmed structural durability and negligible phase transformation after electrochemical testing. Among all synthesized samples, Li<sub>1.167</sub> Ni<sub>0.222</sub> Mg<sub>0.222</sub> Mn<sub>0.388</sub>Co<sub>0.167</sub>O<sub>2</sub> exhibited the best combination of structural stability, electrochemical efficiency, and safety-warning performance. Furthermore, the integrated ECM–FDI framework demonstrated reliable fault detection under different operating temperatures and cycling conditions. The proposed integrated strategy offers a practical pathway toward safer and more intelligent high-energy–density LIB systems for next-generation EV applications.</p>

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Early Safety Warning of Thermal Runaways Explosion in LIBs Containing a Novel Composite for Electric Vehicles: Manufacturing of Temperature & Resistance Sensor

  • 期刊论文

  • 发表日期：

    2026年6月16日

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  • Majid Monajjemi,
  • Fatemeh Mollaamin,
  • Parsa Hosele Pour

摘要

Nowadays, Ni-rich mixed transition-metal cathode materials are extensively investigated for lithium-ion batteries (LIBs) in electric vehicles (EVs) because of their high operating voltage, superior specific capacity, and enhanced energy density. However, their practical application remains limited by structural instability, thermal safety issues, and insufficient early-warning systems against thermal runaway. By this work a combination of {[(1–x–y) LiNi0.333Mg0.333Mn0.333] O2}, xLi2MnO3, yLiCoO2 composite systems were synthesized using the sol–gel method. Proper stoichiometric weights of the LiNO3, Mg (NO3)2 ⋅ 6H2O, Mn (Ac)2 ∙4H2O, Co(Ac)2⋅ 4H2O, Ni(NO3)2⋅6H2O as starting materials of lithium, magnesium, Manganese, cobalt and nickel, in 28 samples of the system, respectively were determined. To improve LIB safety, a multifunctional temperature–resistance monitoring system integrated with resistive room-temperature H2 sensor and equivalent circuit model–fault detection and isolation (ECM–FDI) diagnostics was designed and fabricated. The proposed sensor enabled early detection of lithium dendrite growth through hydrogen evolution prior to smoke generation and thermal runaway. Quantitative analysis showed a minimum detectable dendrite mass of approximately 2.75 × 10−4 mg, providing an effective early-warning window for EV battery protection. Post-cycling SEM and XRD analyses confirmed structural durability and negligible phase transformation after electrochemical testing. Among all synthesized samples, Li1.167 Ni0.222 Mg0.222 Mn0.388Co0.167O2 exhibited the best combination of structural stability, electrochemical efficiency, and safety-warning performance. Furthermore, the integrated ECM–FDI framework demonstrated reliable fault detection under different operating temperatures and cycling conditions. The proposed integrated strategy offers a practical pathway toward safer and more intelligent high-energy–density LIB systems for next-generation EV applications.