Battery pack designs and technical safety requirements are evolving at a rapid pace. Shifts in government policy, sourcing requirements, and consumer expectations are driving designs that are maximizing cell content in packs and introducing new chemistries. These changes can have a profound impact on how thermal propagation may take place in the pack. In this talk, we will compare and contrast the thermal runaway behavior of LFP cells vs. NMC cells and speak about how those differences could translate into new material design and philosophies for how to mitigate these challenges.

Enhancing safety in battery testing processes is crucial to managing high-density testing in controlled, secure environments. This practice involves creating specialized scenarios that ensure safety measures are prioritized and optimized, helping to protect both equipment and personnel. In certain applications, larger batch testing in safely managed environments may be required. We will guide you through the necessary steps to ensure a safer approach to battery testing.

SafeCore by Amionx is a material that is coated on the current collector in a battery cell that is responsive to current, temperature and voltage thresholds being reached. When one or any combination of these thresholds is reached, the material either: 1. Decomposes and cuts the flow of electricity in the cell, or 2. Creates a high impedance environment. In both cases, thermal runaway is prevented. Commercial progress and test reults will be discussed.

Growing public awareness of lithium-ion battery thermal runaway hazards has coincided with increased scrutiny of batteries when they are found at fire scenes. Lithium-ion thermal runaway can occur due to heating from an external fire, even if they are not the cause of the fire. This presentation will encompass many analytical tools that may be relied upon when analyzing the role of lithium-ion batteries at fire scenes, as well as in the post-scene analysis of batteries and devices.

The increasing deployment of energy storage systems (ESS) globally requires a focus on understanding their hazards and ensuring reliable safety systems. Fike will present the dangers & causes of thermal runaway, an unpredictable fire hazard occurring in the lithium battery cells held in an ESS. Backed by years of internal test data, we’ll review the effectiveness of thermal runaway safety solutions recommended by global codes & standards and will analyze various ESS installation scenarios and the comprehensive safety systems we’d recommend ensuring these hazards are mitigated.

Designing better batteries, whether for cell designers or pack designers and integrators, requires a real-world understanding of the battery system being deployed and its influences on performance, reliability, life, and safety. This talk will demonstrate how Gamma Technologies' simulation solutions help drive commercially viable and successful products by expediting time-to-market and minimizing the need for expensive physical testing. Rooted in multi-physics, you will understand how to optimize designs and materials to meet performance requirements and leverage physics-based aging models and operating conditions to study the impact on the battery's lifespan. You will also learn how to combine electrochemical, fluid-thermal, mechanical, and controls to analyze and prevent catastrophic events such as battery thermal runaway propagation and gain deeper insights through an integrated systems approach.

Traditional battery detection methods struggle to achieve non-destructive inspection of battery internals. To address this, TOPSOUND has introduced an innovative ultrasonic detection technology, pioneering its application on battery production lines. This system provides comprehensive pre-inspection solutions for key processes, including slurry bubble detection, electrolyte wetting, degassing quality, and consistency. TOPSOUND's ultrasonic technology fills the gap in quality inspection, helping battery manufacturers reduce costs and enhance product quality more effectively.

The lithium-ion battery market is experiencing explosive growth, projected to reach US$144 billion by 2030, up from an estimated US$65.5 billion in 2024 and US$54.5 billion in 2023. While traditional inspection methods like digital radiography fall short in detecting critical defects, computed tomography (CT) scanning has proven effective for battery integrity verification. However, conventional CT techniques struggle to keep pace with the rapidly accelerating production demands of the electric vehicle (EV) industry. Current offline and sampling-based inspection approaches are insufficient for high-volume manufacturing and are primarily limited to cell development. To address this challenge, Nikon has developed a revolutionary AI-powered CT reconstruction algorithm. This customizable solution delivers significantly improved speed, accuracy, and image quality, enabling efficient high-throughput inspection of lithium-ion batteries.

PACT developed a 100% paper-based solution for L-Ion battery pack safety (TR-Sleeve) that shuts down thermal-run-aways on the cellular level.
The technology is in the coatings that are applied to the paper. When the battery goes into thermal run-away, the coatings are released as a moisture barrier that cools and adds moisture to the environment.

From the same technology PACT developed ThermoShield, a paper based product as a thermal management system for shipping and storing Lithium batteries. This unique invention mitigates thermal run-away by cooling and humidifying the environment. The hot electrolyte gases that escape from a battery condense against the paper. This process prevents the hot gases from finding oxygen and exploding. By controlling the environment, you prevent the explosion and prevent the propagation to other batteries. ThermoShield has been extensively tested: via SAE-G27 tests