Battery Safety Conference, March 29-30, 2022

Cambridge EnerTech’s

Battery Safety

Battery Safety Standards & Testing

MARCH 29 - 30, 2022 | ALL TIMES EDT

As more high-energy density batteries enter the market, it is becoming increasingly important for battery safety testing and regulations to advance along with new technologies to ensure safe battery function and consumer use. This year's Battery Safety conference program, part of the International Battery Seminar & Exhibit, will cover important battery regulations and safety testing necessary to stay up to date with large R&D advancements. Regulatory agencies and associations, cell R&D engineers and reliability engineers will discuss how they are developing robust and reliable tests for the progressively complex cell and pack designs. Maintaining battery pack stability and mitigating thermal runaway to improve safety will also be covered

Tuesday, March 29

7:00 am Registration Open and Morning Coffee (Pre-Function West)

ROOM LOCATION: Timor Sea 1-2


8:05 am

Organizer's Remarks

Victoria Mosolgo, Conference Producer, Cambridge EnerTech
8:10 am

Chairperson's Remarks

Dean D. MacNeil, PhD, Senior Research Officer, National Research Council Canada
8:15 am

Mitigating Thermal Runaway & Testing

Dean D. MacNeil, PhD, Senior Research Officer, National Research Council Canada

During our work within Global Technical Regulations on EV safety and various international standards, a new approach towards thermal runaway/propagation testing of advanced battery packs and systems was developed. We have pioneered a rapid heating testing methodology and in this talk, we will work through its theory and testing criteria while providing examples at the full operational pack and system level. The methodology and related test requirements have been adopted by a number of test agencies worldwide.

8:45 am

Numerical Simulations of Thermal Runaway and the Resulting Sparks

Jennifer Wen, PhD, Professor, Engineering, University of Warwick

The presentation reports numerical and experimental studies of thermal runaway (TR) induced by thermal/nail penetration abuse. It includes some measurements as well as the development and validation of a CFD model for TR evolution and transport of the ejected hot sparks in an enclosed cell cluster. Further analysis in which the validated model is used to fill important experimental gaps will also be discussed in the context of battery thermal management.

9:15 am

Thermal and Mechanical Safety Assessment of Commercial Cylindrical Lithium-Ion Batteries by Means of Accelerating Rate Calorimetry (ARC)

Sebastian Ohneseit, Group Batteries Calorimetry and Safety, Institute for Applied Materials – Applied Materials Physics (IAM-AWP), Karlsruhe Institute of Technology (KIT)

Thermal runaway behavior was evaluated by two methods, both using Accelerating Rate Calorimetry (ARC). With the Heat-Wait-Seek (HWS) test, thermal abuse was studied and exothermal reaction temperature rates were evaluated and compared for different cathode materials and states of charge. In addition, nail penetration tests were performed to evaluate the safety during mechanical abuse by puncturing and short-circuiting the cell with a steel nail, accompanied by temperature and video recording.

9:45 am Networking Coffee Break (Pre-Function West)


10:15 am

Li-ion Battery State of Health and State of Safety Monitoring using Online Aging Models, Advanced Sensing, and Machine Learning

Kandler Smith, PhD, Senior Engineer, Energy Storage, National Renewable Energy Laboratory

Safety events are often preceded by some weakly observable electrochemical indicating, for example, plated lithium or an internal short. To detect such a signal, we propose algorithms combining aging reference models and real-time measurements. Reference models indicate the expected performance and aging behavior, while real-time measurements provide corrections to the model and flag unexpected behavior. Machine learning is used both to identify models and interpret measurements.

10:45 am

Li-Ion Battery Thermal Runaway Initiation and Propagation

Peng Zhao, PhD, Associate Professor, Mechanical, Aerospace & Biomedical Engineering, University of Tennessee

This talk focuses on the thermochemical behavior of Li-ion batteries and includes three parts: first, the threshold condition of thermal runaway is computationally identified based on minimum ignition energy. Second, mild combustion is introduced, to mitigate thermal runaway and guide battery design. Last, a reaction-conduction theory is developed to describe thermal runaway initiation and propagation.

11:15 am

Measurement and Understanding of Surface and in situ Cell Temperature and Their Implications for Cell Safety and Rate Capabilities

Alexander Roberts, PhD, Associate Professor, Institute for Clean Growth and Future Mobility, Coventry University

The temperatures experienced by a cell during operation are critical to safety, performance, and lifetime. To better understand thermal properties and their effects on cell performance we expand on conventional single point measurement to internal temperature monitoring through in situ sensoring, with complimentary cell mapping via thermal imaging. With this enhanced understanding of localised temperatures, improvements in safety and performance, particularly in fast charging, high power application, can be achieved.

Terence Kearns, Manager Business Development, WEVO-CHEMIE GMBH

Wevo develops and produces resin systems as well as adhesives and sealants primarily for use in electrical and electronic equipment, and in particular for automotive electronics. Here, Wevo products protect sensitive electronic components against humidity, chemicals, high temperatures, dust and foreign matter. In short, Wevo products ensure safety and efficiency.

John Williams, Vice President, Technical Services, Aspen Aerogels

The Chinese government mandates that passengers must have a 5-minute window to exit their vehicle after detection of thermal runaway. While this is a step forward, a better goal is to stop thermal propagation. Single-cell thermal runaways that propagate to module-, pack-, or vehicle-level will, even at low incident rates, dampen acceptance of BEVs. Discover how aerogel-based thermal barrier materials can help achieve this goal within space, weight, and cost constraints.

12:15 pm Grand Opening Luncheon in the Exhibit Hall (Sponsorship Available) (Pacifica 6)
1:15 pm Dessert Break in the Exhibit Hall with Poster Viewing (Pacifica 7-12)



1:45 pm

Shep Wolsky Battery Innovator Award Presentation

Craig Wohlers, Executive Director, Conferences, Cambridge Enertech
1:50 pm

LG's Vision of Electrification: Innovation, Evolution, and Collaboration

Denise Gray, President, LG Energy Solution Michigan, Inc., Tech Center

Battery technology innovation has been an enabler for alternative propulsions and mobility solutions. The baseline has been established, but, the outlook is limitless. Amazing researchers and engineers have developed the technology to meet propulsion and mobility requirements. The mobility solutions available to the consumers will be breathtaking.  

2:20 pm

More than a Million Miles and a Century of Life

Jeff Dahn, FRSC, PhD, Professor of Physics and Atmospheric Science, NSERC/Tesla Canada Industrial Research Chair, Canada Research Chair, Dalhousie University

Lithium-ion cells can have incredible cycle (>10,000) and calendar lives (>40 years). I will explain how such long-lived cells can be made. The common belief is that only 800 charge-discharge cycles is enough for EVs so why do we need such amazing cells? Ninety percent of all Li-ion cells produced in 2030 will be used in EVs, so vehicle to grid storage is absolutely required to incorporate more renewables on the grid to reduce dependency on fossil fuels. Such awesome Li-ion cells are needed so EV batteries can support a large fraction of their charge-discharge cycles while parked.

2:50 pm

Keynote Panel Discussion: Overcoming the Challenges of Meeting Global Demand for Sustainably Scaled Advanced Battery Materials

Panel Moderator:
Vineet Mehta, Director, Battery Technology & Powertrain Architecture, Tesla

The demand for advanced batteries continues to grow exponentially driven by electric vehicles as well stationary storage. Creating a sustainable supply of battery materials at a global scale is critical to success. This panel of experts will explore the pathway to sustainability through new materials development, recycling, 2nd use enabled by exceptional lifetime, and sustainable mining.

JB Straubel, Co-Founder & CEO, Redwood Materials
Jeff Dahn, FRSC, PhD, Professor of Physics and Atmospheric Science, NSERC/Tesla Canada Industrial Research Chair, Canada Research Chair, Dalhousie University
Jeffrey S. Spangenberger, Director, ReCell Center, Argonne National Laboratory
3:30 pm Transition to Conference Programs

ROOM LOCATION: Timor Sea 1-2


3:40 pm

Chairperson's Remarks

Judith Jeevarajan, PhD, Vice President, Research, Electrochemical Safety Research Institute (ESRI), Underwriters Laboratories, Inc.
3:45 pm

Failure Analysis – What to Do When Something Goes Wrong

John Copeland, Founder & CTO, Energy Assurance LLC

Your product is only as good as the battery! Unfortunately, battery product failures can happen at any time. What should you do when you experience a battery failure? Why even bother with battery failure analysis? What can it teach you about selecting the correct battery solution – and battery supplier – for your products? Should your battery supplier or a 3rd party be used to conduct the investigation? One of the compelling reasons for a detailed failure analysis is it results in better yields, profitability, and better business. Failure analysis leads to knowledge, which leads to improvement

4:15 pm

Smoke and Fire Characterization for Lithium-Ion Cell and Battery Fires

Judith Jeevarajan, PhD, Vice President, Research, Electrochemical Safety Research Institute (ESRI), Underwriters Laboratories, Inc.

The fire and smoke components released during a lithium-ion fire have been characterized and the challenges of putting out such a fire will be discussed. Cells of different cathode chemistries and at different states of charge were taken into thermal runaway and the smoke and fire composition was analyzed. ASTM methods were used to determine the lower flammability limits for the gases released and the data will be shared during the talk.

4:45 pm

Analyzing the Effect of Varying Crush Speed on Battery Failure Behavior

Bhavya Kotak, Research Associate, Safe Electromobility, Technische Hochschule Ingolstadt

Despite having multifarious Electric Vehicle (EV) battery testing standards, there have been, few severe accidents noticed recently that have resulted in some reservations by the EV consumers, hindering the deployment of the EV. Hence, it becomes crucial to experimentally investigate the speed at which the batteries are crushed to understand its failure mechanism and to look into the safety of EV consumers and the necessity for the harmonization of multifarious globally available standards.

5:15 pm Welcome Reception in the Exhibit Hall with Poster Viewing (Pacifica 7-12)
6:30 pm Interactive Roundtable Discussions (Pacifica 6)

Roundtable discussions are informal, moderated discussions with brainstorming and interactive problem solving, allowing participants from diverse backgrounds to exchange ideas and experiences and develop future collaborations around a focused topic.

TABLE 1: Battery Raw Materials Supply Chain

Robert M. Privette, Manager, Business Development, Rechargeable Battery Materials North America, Umicore USA, Inc.

TABLE 2: Li-Ion NMC Fast Charging New Cells for E-Mobility

Shmuel De-Leon, CEO, Shmuel De-Leon Energy Ltd.

TABLE 3: Li-Ion Battery Safety: Prediction, Prevention, Levels and Legalities

John Zhang, PhD, Senior Technology Executive Officer, Asahi Kasei SSBU Polypore, Celgard LLC

TABLE 4: Silicon Anodes and Cells

Benjamin Park, PhD, Founder & CTO, Enevate Corp.

Table 5: Electrolyte Developments: New Components and Approaches

Sam Jaffe, Vice President, Battery Solutions, ESource

Table 6: Battery Pack System Cost and Safety – Will Future xEV Battery Packs Increase in Complexity or Simplify and How Will Cost and Safety Be Impacted?

Kevin Konecky, Battery and Energy Storage Systems Consultant, Total Battery Consulting

Table 7: Battery Degradation and Safety

Craig B. Arnold, PhD, Professor, Mechanical & Aerospace Engineering, Princeton University
John Williams, Vice President, Technical Services, Aspen Aerogels
  • When designing for thermal runaway, should we assume active cooling is available?
  • Have you seen ineffective gas management undermine defenses against thermal propagation?
  • Do you think stopping, rather than delaying, thermal propagation is a realistic goal?
7:15 pm Close of Day

Wednesday, March 30

7:45 am Registration Open & Morning Coffee (Pre-Function West)

ROOM LOCATION: Timor Sea 1-2


8:25 am

Chairperson's Remarks

Donal P. Finegan, PhD, Staff Scientist Batteries, Electrified Transport, National Renewable Energy Laboratory
8:30 am

The Battery Failure Databank: An Open-Access Database of Thermal Runaway Data from Lithium-Ion Batteries

Donal P. Finegan, PhD, Staff Scientist Batteries, Electrified Transport, National Renewable Energy Laboratory

Understanding the risks associated with thermal runaway of LIBs is critical for designing safe cells and battery systems. The thermal response of cells can greatly vary for identical cell designs tested under identical conditions, the distribution of which is costly to fully characterize experimentally and cannot be captured by deterministic models. The Battery Failure Databank contains robust, high-quality data from hundreds of abuse tests spanning numerous commercial cell designs and abuse testing conditions. Data was gathered using a fractional thermal runaway calorimeter and contains the fractional breakdown of heat and mass from ejected and non-ejected cell contents, as well as high-speed radiography of the internal structural response of cells during thermal runaway. This presentation will provide an overview of the Battery Failure Databank as well as insights gained from in situ radiography of internal causes of outlier battery failure events.

9:00 am

Are Solid-State Batteries Safer Than Lithium-Ion Batteries?

Alex Bates, PhD, Energy Storage Safety & Reliability, Sandia National Laboratories
Bill Davidson, COO, Amionx

Safety is critical to the wide adoption of lithium battery technology in all applications.  This talk focuses on how an internal fuse, called SafeCore, within the individual battery cell can help prevent thermal runaway due to overcharge or internal short and can delay thermal runaway in certain high temperature environments.  Cell abuse data, Accelerating Rate Calorimetry testing and SEM images on cells with SafeCore and without will be reviewed.  

Bob Laudisi, Applications/Mechanical Engineering, Sales, Associated Environmental Systems

Practicing and utilizing concepts in lean methodologies lead naturally to safer, and more efficient battery testing. By creating scenarios for managing high-density testing in small batches, it increases safety and reduces cost per channel.

10:00 am Coffee Break in the Exhibit Hall with Poster Viewing (Pacifica 7-12)


10:45 am

Fail-Safe Design of Battery Racks for Behind-the-Meter Energy Storage

Chuanbo Yang, PhD, Senior Engineer Energy Storage, Energy Conversion & Storage Systems Center, National Renewable Energy Laboratory

Behind-the-Meter Storage (BTMS) systems are envisioned to be the solution that can minimize grid stability challenges posed by high penetration of electrical vehicles in the market. However, the hazards associated with lithium-ion batteries used in BTMS applications become reality. In light of this, a strategy based on leveraging advanced thermal design and battery management system is being developed to enable a fail-safe rack design.

11:15 am

Modeling of Thermal Runaway Propagation in a Pouch Cell Stack

Ofodike Ezekoye, PhD, Professor, Mechanical Engineering, University of Texas at Austin

Characterizing propagation of a thermal runaway hazard in cell arrays and modules is critical to understanding fire hazards in energy storage systems. In this talk, the thermal runaway propagation of a pouch cell array has been examined by developing a 1D finite difference model.

11:45 am

Reducing the Risk of Battery Fires with Multi-Functional Venting Units

Michael Harenbrock, PhD, Principal Expert, Engineering Electric Mobility, MANN+HUMMEL GmbH

To protect passengers from the negative impact of thermal runaways, standards like GB 38031-2020 are introduced. One way to comply with these is to prevent hot particles, created by cell explosion, from being ejected into the environment, so they cannot ignite flammable gas/air mixtures outside the pack. Adding hot particle filter functionality to venting units as shown in the presentation is an innovative solution addressing these new requirements.

Shih-Chieh Liao, PhD, Chief Technical Advisor, Research & Development, HCM CO., LTD.

I will present LMFP/NMC cells that can provide a total solution to safety, capacity, power, life and cost issues with EV batteries. The 4V olivine-structured LMFP, which we synthesized, had a discharge capacity of 150 mAh/g as well as excellent rate capability (>15C) and life >5000 cycles. We found that LMFP/NMC cells with a dual-layer electrode structure exhibited much improved safety, rate capability and cycle life, compared with the LMFP/NMC blend and NMC counterparts. The underlying mechanisms will be discussed.

12:45 pm Networking Luncheon (Sponsorship Available) (Pacifica 6)
1:45 pm Dessert Break in the Exhibit Hall with Poster Viewing (Pacifica 7-12)



2:25 pm

Organizer's Remarks

Craig Wohlers, Executive Director, Conferences, Cambridge Enertech
2:30 pm

Building Gigafactories – Lessons Learned and the Future of EV Battery Manufacturing

Panel Moderator:
Celina Mikolajczak, Chief Manufacturing Officer, QuantumScape

The transition to vehicle electrification has generated a rapidly increasing demand for battery cells and packs. The key to producing cells at the volumes that will be required will be the building and implementation of gigafactories on a global scale. This panel of international experts who have been directly involved in building existing gigafactories will share their insights on what they have learned and how they see the future of electrification.

Hailong Ning, PhD, Head of Battery Manufacturing Technology and Engineering, Nio
Kenzo Nagai, Process Engineer, Cell Engineering, Hatch
Ken Zemach, PhD, Vice President Quality, Northvolt
Victor Prajapati, PhD, Senior Director, Cell Engineering, Rivian
Evan Horetsky, Partner, Mckinsey & Company
4:15 pm Close of Battery Safety Conference
3:30 pm Refreshment Break in the Exhibit Hall with Poster Viewing (Pacifica 7-12)