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

作者：Hong Zhao, Xiangkun Bo, Zhiguo Zhang, Li Wang, Walid A. Daoud, Xiangming He · 发表于：Battery energy · 年份：2025 · DOI：10.1002/bte2.20250036 · 被引用次数：13 · 研究领域：Advanced Battery Technologies Research、Electric Vehicles and Infrastructure、Advanced Battery Materials and Technologies

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 0.8 Co 0.1 Mn 0.1 ‐based batteries is eightfold faster than that of LiFePO 4 ‐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 ac...