Insight Into Puncture-Induced Thermal Runaway in Lithium-Ion Batteries to Reduce Fire Risks in Electric Vehicle Collisions

Abstract

Lithium-ion batteries (LIBs) power electric vehicles through exceptional energy density but pose critical safety risks when mechanically compromised, particularly through nail penetration-induced thermal runaway. This review synthesizes experimental and modeling studies to establish the thermal runaway initiation hierarchy: (1) State-of-charge (SOC) (doubles thermal runaway probability at over 60% SOC), (2) cathode chemistry (thermal runaway propagation of LiNi_0.8Co_0.1Mn_0.1-based batteries is eightfold faster than that of LiFePO₄-based batteries), (3) nail properties (the possibility of short-circuit current of steel-based batteries is 40% higher than that of copper-based batteries), and (4) penetration dynamics (depth's impact is more than that of separator thickness in triggering cascading failures). Thermal runaway mechanisms involve synergistic electrochemical-thermal-mechanical coupling, where localized heating (higher than 1 × 10⁴ K/s) initiates separator collapse (80°C-120°C) and electrolyte decomposition (200°C). Mitigation strategies focus on mechanically graded separators (SiO₂/polymer composites: increasing 180% in puncture resistance); shear-thickening adhesives reducing impact forces by 35%-60%; halogen-free electrolytes within a 2 s self-extinguishing time; and solid-state architectures showing 0% thermal runaway incidence in nail penetration tests. Critical gaps persist in standardizing penetration protocols (velocity: 0.1-80 mm/s variations across studies) and modeling micro-short circuits. Emerging solutions prioritize materials-by-design approaches combining sacrificial microstructures with embedded thermal sensors. This analysis provides a roadmap for developing intrinsically safe LIBs that maintain energy density while achieving automotive-grade mechanical robustness (ISO 6469-1 compliance), ultimately advancing collision-resilient electric vehicle battery systems.

Keywords

internal short circuit / lithium-ion batteries / mechanical safety / nail penetration / thermal runaway

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