Inside Lithium-Ion Safety Testing

Lithium-ion (Li-ion) batteries have become an everyday component of our modern world, powering everything from smartphones to electric vehicles. Their widespread use in daily life makes safety a priority for manufacturers and consumers alike. This infographic explores why battery safety is important and highlights the testing methods that ensure the technology that powers our devices remains safe. As Li-ion batteries continue to power our world, understanding and maintaining their safety remains crucial. Through rigorous testing and continuous innovation, scientists and engineers work tirelessly to ensure these powerful energy sources remain safe in our pockets and our lives. These crucial safety evaluations rely on cutting-edge battery testing equipment, specialized laboratories and advanced analytical tools – sophisticated technology that ensures tomorrow’s batteries meet the highest standards of performance and safety. References 1. Warner JT. Lithium-Ion Battery Chemistries: A Primer. Elsevier; 2019. 2. International Electrotechnical Commission. Standard IEC 62133-2:2017. Iecee.org. Published 2017. http://www.iecee.org/certification/iec-standards/iec-62133-22017 batteries Battery Safety testing Inside Lithium-Ion understanding lithium-ion cathode (positive electrode): anode (negative electrode): electrolyte: separator: Separator Charging Discharging Separator 1. Lithium ions move from the cathode to the anode 2. Electrons flow through the external circuit 3. Energy is stored in the battery’s chemical structure Cathode Material Anode Electrolyte Material Electrolyte Electrolyte Electrolyte Electrolyte Typically made of lithium metal oxide, this is responsible for storing and releasing lithium ions. 1. When powering a device, lithium ions move back from the anode to the cathode 2. Electrons flow through the device, providing electrical power 3. Energy is released as ions travel through the electrolyte Usually composed of graphite, this lets electric current flow into the battery from an external circuit. A liquid or gel-like medium that allows lithium ions to travel between electrodes. A thin membrane between the electrodes which prevents direct electrical contact and only allows lithium ions to pass through. Electrolyte Li+ Li+ e- ee- e- e- ee- e- e- ee- e- Li+ Li+ Li+ Li+ Separator battery Safety Risks The key components of Li-ion batteries are highly reactive and are only separated by thin barriers, all of which are contained within a sealed unit. When these systems operate as designed, they’re remarkably safe and efficient. However, if any component fails, the stored energy can be released in uncontrolled and unexpected ways. Thanks to their high energy density, good storage characteristics and long cycle life, Li-ion batteries are essential for our modern lifestyle, powering a diversity of devices, from electric vehicles to watches, laptops and smartphones. All of this power relies on the electrochemical behavior of the lithium metal ions contained within the battery.1 Short circuits Thermal runaway Thermal runaway occurs when a battery’s internal temperature spirals out of control. This begins when temperatures rise beyond the battery’s designed safe operating range, creating a self-perpetuating cycle, potentially leading to smoke, fire or even explosive conditions. Short circuits are created when an unintended electrical path forms between the battery’s positive and negative terminals. This leads to an uncontrolled discharge of electrical energy that generates extreme heat. Mechanical damage When a Li-ion battery is charged beyond its designed voltage limit, its internal chemistry begins to break down. This can lead to short circuits, reduced capacity and increased risk of thermal events. Overcharging Any physical impact, compression or puncture can compromise the separator between electrodes. Even minor damage can create internal shorts, disrupt ion flow or create points of weakness that may lead to battery failure. how do you knowb aattery is safe? Rigorous testing protocols ensure batteries meet international safety standards.2 Each battery design undergoes multiple testing phases before approval. These tests simulate real-world conditions and potential abuse situations, helping manufacturers identify potential failure modes and validate safety features before batteries reach consumers. ensures that batteries operate safely within their specified voltage and current ranges and that protection mechanisms function correctly when these limits are exceeded. prevents batteries from being damaged by charging them too much. testing determines how an electrical system responds to short circuit. testing confirms that the battery does not malfunction or become damaged under voltage fluctuations. electrical testing Overcharge protection Short circuit response Voltage tolerance simulates various real-world scenarios where batteries might experience physical trauma or pressure. evaluates how batteries respond to temperature changes and thermal stress. under controlled pressure. tests the battery at sustained high temperature conditions. from various heights and angles. involves repeated heating and cooling between −20 °C and +60 °C. evaluation determines the strength the film that separates the electrodes. ensures internal chemical changes are as expected at a range of temperatures. Mechanical testing Thermal testing Crush testing Heat exposure Drop testing Temperature cycling Puncture resistance Thermal stability monitoring we all benefit from Safer Batteries Steven Gibney, PhD Illustrated by AnnaMaria Vasco