EV Battery Packaging to Prevent Thermal Runaway

Energy storage system with automated fire suppression to extinguish battery fires early and prevent explosions. The system uses sensors to detect abnormal temperature or size changes in the battery module. When these thresholds are reached, it activates a fire extinguisher to spray agent on the module. This suppresses fires before they spread or escalate. The system also alarms when module expansion is detected.

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Rechargeable battery design to improve high temperature safety by providing a mechanism to discharge internal heat and gas when the battery overheats. The battery has a heat dissipating portion filled into an opening in the cap plate that seals the battery. This opening allows heat and gases to escape during melting to prevent explosions. The cap plate also has a notch groove around the opening. The heat dissipation film on the battery side helps further dissipate heat. By actively venting heat and gases instead of allowing internal pressure to build, the battery prevents catastrophic failures at high temperatures.

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Impact resistant thermal barrier coating for batteries to prevent thermal runaway propagation and fire spread. The coating contains zirconium silicate as a filler and an inorganic binder like alkali silicate or a sol. The zirconium silicate provides high impact resistance and thermal resistance at elevated temperatures, preventing particle blast forces from propagating thermal runaway. The coating can be applied to battery components like cell separators and compartment lids to isolate fires and reduce the chance for catastrophic thermal runaway.

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Battery pack design to improve thermal management of the cells and bus bar by integrally coupling the cell holder and bus bar with a heat-conduction accelerating feature. The cell holder and bus bar are molded together, with a portion of the bus bar that connects to the holder having an enhanced thermal conductivity feature. This accelerated heat transfer quickly and effectively moves heat from the bus bar to the cell holder, which has a larger heat capacity. The heat is then dissipated through air exchange with the environment. This prevents overheating of the cells and bus bar by quickly transferring and dissipating heat.

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Battery pack design with simplified electrical and cooling connections between cells to enable uniform cooling without temperature dispersion, while adaptively providing capacity and output based on requirements. The pack has cells with internal parallel and series connections, individualized cooling plates, and parallel cell streams connected serially. This allows customized cell configurations and uniform cooling by avoiding hotspots. The simplified electrical connections enable adaptive capacity and output matching by adjusting the number of cells in each stream.

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End cover assembly for battery cells with improved sealing and safety. The assembly has a cover plate with a pressure relief hole, a fixed member with through holes, and a gas permeable membrane covering the hole. The membrane edge is connected to the fixed member and partially embedded in a through hole. This prevents the membrane from moving relative to the fixed member as internal cell pressure acts on the membrane. This prevents separation of the membrane from the cover plate and leaks.

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Housing assembly for battery cells that improves pressure resistance and air tightness to prevent cell damage due to expansion. The assembly has a rough region on the inner and outer surfaces of the cover and body where they connect. This roughened joint increases friction force as pressure increases, preventing deformation and sliding. It also uses a sealing member between the body and cover to further improve air tightness. The rough joints and sealing member prevent the cover from deforming and sliding as the cell expands, improving reliability and preventing damage.

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Heat dissipation material with low adhesion force that can be used in electric/electronic devices like batteries. The material has a resin composition with a polyol-based polyester resin as the matrix and an amine-based curing agent. The resin composition has low adhesion force to surfaces like polyester and aluminum due to its unique formulation. The low adhesion property is achieved without using expensive silicone binders or plasticizers that can damage the material or elute during use. The composition can be cured to form a cured body with desirable thermal conductivity, hardness, and curvature for heat dissipation applications.

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A high-speed semiconductor memory design that reduces charging and discharging times of internal buses to improve overall memory access speed. The memory has a sense amplifier in one area connected to the memory cells via a bitline. A separate hookup circuit in another area controls connection between the bitline and sense amplifier. A transistor in a third area connects the sense amplifier and hookup circuit. This layout positions the transistor close to the center of the buses to shorten charging and discharging distances.

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A power storage module with improved adhesion between the insulating sheet and metal components. The module has a binding bar and stack of cells with thermocompression-bonded insulating sheets on the metal surfaces. The insulating sheets have thermosetting properties. This facilitates adhesion compared to using tapes or adhesives, especially avoiding foreign material contamination. The insulating sheets can also have flame retardant coatings for added safety. The thermocompression bonding process involves heating and compressing the insulating sheet onto the metal surface.

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Battery cell design with enhanced safety and improved cooling performance. The battery cell has a tab protection module inside the cell case that covers part of the electrode tab. This module absorbs external forces and prevents tab separation. It also provides a heat dissipation path for the tab area. This improves safety by preventing tab damage from external impacts and prevents internal heat buildup.

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Battery pack design with improved energy density, cost, cooling, and size compared to conventional battery packs. The pack has a cell assembly with multiple cells, a busbar on one side, a cooling unit between the cells, and a cell partitioning unit. This eliminates the need for a separate frame and reduces size. The cells are supported by a cell support unit and covered by a filling member. This simplifies assembly, improves pack integrity, and allows higher cell density.

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Battery module design with improved expansion force release and connection reliability. The battery module has a frame with mounting grooves for the cable ties. The cable ties have an inner and outer section made of different materials. The inner section is closer to the battery cells and provides high connection reliability. The outer section is further from the cells and allows expansion force release. The frame grooves restrict movement of the inner section while allowing the outer section to expand. This prevents inner tie breakage while releasing cell expansion forces.

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Optimizing image stabilization in cameras with wide-angle lenses to reduce blur at the edges while still correcting central blur. The technique involves dynamically adjusting the ratio of image stabilization (IS) and in-lens image stabilization (IIS) when the camera shakes. The IS corrects central blur while the IIS corrects peripheral blur. The ratio is set based on the different image shift sensitivities at central vs peripheral image positions. This balances central blur reduction with peripheral blur reduction to minimize overall image blur across the frame.

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Reducing duplicate records in a threat management system when multiple virtual machines are connected to an enterprise network. The system detects new virtual machines joining the network, creates a unique identifier based on the template and user, compares against existing records, and if a match is found, merges the records instead of creating duplicates. This prevents accumulation of duplicates when users connect multiple virtual machines concurrently.

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System and method to efficiently process wide-angle camera images using a model trained for normal cameras. The technique involves generating multiple virtual images from the wide-angle image, each with a smaller resolution, and feeding these to the model. This allows analyzing the wide-angle scene with minimal loss of information compared to scaling down the wide-angle image. The virtual images can be generated by dividing the wide-angle frame into sections and copying the corresponding area into smaller frames. This enables using existing normal camera models for wide-angle surveillance without needing specialized wide-angle models.

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High performance heat control members for separating battery cells or insulating battery components that have favorable resistance to heat propagation and fire propagation while minimizing thickness and weight of materials used. The members include reinforced aerogel composites with durability, compressibility, and thermal insulation properties for battery applications. The aerogel composites have a reinforcing phase like fibers or open-cell macroporous materials to enhance mechanical properties compared to pure aerogels. The reinforced aerogel composites have compressibility less than 25% at 25 kPa, density less than 0.3 g/cm3, and thermal conductivity less than 25 mW/mK.

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Safety-improved battery pack for electric vehicles that prevents thermal runaway propagation and minimizes damage when it occurs. The pack has a venting inducing frame around the battery modules that guides venting gas in a predetermined direction. Quenching members inside the frame absorb flaming venting gas and prevent it from reigniting. This prevents thermal runaway from spreading between modules and reduces damage if it does occur. The pack also has a housing to contain the venting and quenching components.

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Composite material, composite material layer, and thermal barrier composite for high temperature applications like battery packs. The composite has a silicone matrix, reinforcing filler, and a ceramization filler composition. The ceramization filler contains components that promote ceramization, a flux to aid sintering, and a flame retardant. This enables the composite to form a dense ceramic barrier at high temperatures, improving thermal barrier performance compared to traditional silicone-based materials.

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Battery cell electrode design to prevent thermal runaway and short circuits. The electrode contains a positive temperature coefficient (PTC) material that increases resistance at elevated temperatures. The PTC material can be added in several ways: coating the active material particles, mixing PTC particles with the active material, or as a separate layer between the active material and separator. This provides a self-heating mitigation mechanism in the electrode that prevents thermal propagation and short circuits in case of overheating or penetration.

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Active thermal management system for batteries that allows extended life and performance outdoors by actively removing heat from the batteries. The system uses thermal conduits and thermoelectric coolers to transfer heat from the batteries to external coolers. This prevents environmental heat from getting into the batteries and allows precise control of battery temperature. It also prevents explosive venting by isolating degraded cells. The system allows long-term outdoor operation of batteries without maintaining insulation or maintaining battery pack temperatures in extreme environments.

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A battery module design to prevent thermal runaway and propagation in battery packs by using a slit with a lower melting point polymer between cells. The module has a cell assembly with thermal transfer blocking assemblies between cells. The module housing has a slit facing each assembly. A thermally conductive polymer with a lower melting point than the housing is filled in the slits. If a cell experiences thermal runaway, the polymer melts and blocks heat transfer to adjacent cells through the slit. This delays thermal propagation compared to a solid housing.

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Reducing explosion risk in rechargeable lithium batteries by coating the inner surface of the battery case with metal organic framework (MOF) materials. The MOFs, like ZIF-8, MOF-177, Al-MIL-53, and Fe-BTC, are nanoporous materials that can capture and trap gases when the battery overheats and generates large amounts of gas during thermal runaway. Coating the inner surface of the battery case with these MOFs prevents the trapped gas from rapidly increasing pressure and causing explosion.

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A cover plate design for battery cells to mitigate explosion hazards and prevent ejecta spreading during thermal runaway. The cover plate has an uneven shape with a sinking table and a raised boss. The explosion-proof grooves are located on the boss and the sinking table. When the cover plate pressure relieves, the sinking table deforms more than the boss due to geometry, causing the explosion-proof grooves to burst first from the sinking table. This directed burst prevents random ejecta dispersal from exploding cover plates.

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An electric energy storage system for a vehicle like a truck or bus that uses multiple containers connected together to improve safety and reliability. The storage system has multiple battery modules in separate containers that are interconnected and sealed. This allows individual module failure to be contained while maintaining overall system operation. The containers are fastened together to equalize potential, align with centering elements, and seal with frames. It also provides cooling/heating plates, insulation, and covers for the containers. The modular container design enables scalability and serviceability. The storage can be mounted on the vehicle frame or roof.

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A battery pack design with an improved gap pad between the battery cells and the pack housing. The gap pad has sections that correspond to the exposed areas of the battery cells on each side. This allows the gap pad to fully cover and protect the cell edges when the pack is assembled. The pad sections are preformed with bend lines to simplify assembly. The pad bends and aligns with the cell exposed areas during pack assembly. This ensures consistent expansion and compression protection around the cells.

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Battery pack design to mitigate fire risk from volatile electrolyte leakage. The pack enclosure contains absorbent material that traps flammable electrolyte vapor if it leaks from the cells. This prevents the vapor from accumulating and potentially igniting. The absorbent material inside the pack catches any leaked volatile electrolyte components before they can build up and pose a fire hazard.

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Secondary battery design to improve safety and reduce internal short circuit risks. The battery has a thicker tab, adhesive with a specific melting point range, and an interleaf between the positive and negative tabs. The thicker tab reduces heat generation during short circuits. The adhesive melts at 135-165°C to create a venting channel. The interleaf prevents electrolyte ingress and lithium plating. This combination lowers resistance, reduces heat, prevents venting failures, and improves safety compared to thinner tabs and lower melting adhesives.

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Circular configuration of battery cells in an aircraft electrical storage system (ESS) for electric aircraft. The ESS uses battery modules with cylindrical pressure vessels containing radially distributed battery packs around a central cooling channel. This circular layout allows even cooling and explosion containment. It enables thinner, lighter, and cheaper pressure vessels compared to flat layouts. The cells connect to the channel using conductive components with lower melting points than cell temps. This prevents thermal runaway spread.

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Container design to prevent propagation of thermal runaway between electrochemical cells or batteries inside. The container has a molded body and cover made of a high thermal conductivity material. The body has vertical receptacles for the cells and internal walls separating them laterally. The cover has passages above the receptacles for cell portions to protrude. A vent allows gases to escape. Seals between receptacles and headspace are breakable and selectively permeable to prevent matter transfer. This prevents thermal runaway and material spread between cells.

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A secondary battery pack for electric vehicles that improves thermal management to prevent runaway cell temperatures and propagation of thermal events. The pack uses a syntactic foam made of hollow glass beads in a silicone binder to insulate the battery cells. This foam provides better low-temperature insulation compared to standard foams. It also minimizes thermal propagation between cells. The pack can have coolant channels and heat dissipation members to further manage cell temperatures. The syntactic foam also helps dampen drivetrain oscillations.

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Lithium-ion battery design with improved thermal management to prevent hot spots and overheating during high power discharge. The battery has electrodes that fold over instead of using tabs to make electrical contact with the end caps. This provides a larger contact area between the electrode and end cap, allowing more uniform and efficient current flow without localized hot spots. It prevents overheating compared to traditional batteries with small tabs.

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Battery pack design for high voltage battery systems that prevent dielectric breakdown and insulate against high voltages. The battery pack has a frame with insulating properties that supports the battery module. It also has a sheet member in close contact with the module bottom that forms a heat transmission path. This isolates the pack from high voltages and allows heat dissipation without insulation breakdown. The sheet member and frame insulate the pack internals from external surfaces.

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The advancement of electric and solar vehicles demands efficient sustainable thermal management solutions to ensure optimal battery performance, safety, longevity. This chapter presents a comprehensive exploration hybrid systems (HTMS) employing nano-enhanced phase change materials (nano-PCMs) as next-generation strategy for effective cooling. Nano-PCMs combine the latent heat storage capability traditional PCMs with superior conductivity nanomaterials, thereby overcoming limitations conventional cooling systems. integration passive active control methods within HTMS is examined, highlighting improved temperature uniformity, accelerated dissipation, enhanced energy efficiency under varying operational conditions. Emphasis placed on material synthesis, thermophysical characterization, system-level modeling nano-PCM-based architectures tailored solar-powered vehicle platforms. role nanomaterials such graphene, carbon nanotubes, metal oxides in augmenting performance analyzed, along techno-economic considerations real-time testing data. also addresses design challenges, environmental im... Read More

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A passive thermal management system for lithium-ion batteries in portable electronic devices that prevents overheating and thermal runaway without active cooling or heavy components. The system uses a specially designed fabric made of ultra-high molecular weight polyethylene (UHMWPE) with directional thermal conductivity. The fabric surrounds the battery and provides a long thermal path with high conductivity in the battery's main direction of heat generation. The UHMWPE fabric absorbs and conducts the heat away from the battery as it generates it, preventing hotspots and thermal runaway. The fabric's low density and floating property make it neutrally buoyant for marine applications.

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The shift towards electric mobility needs extensive research into battery modules, particularly in relation to safety due the high energy density of Li-ion batteries. Battery casings must be able protect module from external impacts while also containing any potential danger event internal failure. This study presents a comprehensive qualitative screening thermoset and thermoplastic carbon fiber-reinforced polymers (FRP) used automotive aerospace applications under thermal runaway (TR) conditions, identify suitable materials for enclosures. test setup is an adaptation UL 2596 standard with hexagonal array seven 21700-format cells. results indicate that CF-PEEK, CF-PPS, aerospace-grade epoxy, CF-EP str (primary structural material) effectively contain TR low damage using current setup. Medium was observed CF-PC, CF-bio-based phenolic, non-structural CF-epoxy CF-PA6 failed TR. serves as initial process narrow down further in-depth analysis, emphasizing need reproducible events accurate assessment.

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Abstract Thermal runaway in lithium-ion batteries is a critical safety concern for the battery industry due to its potential cause uncontrolled temperature rises and subsequent fires that can engulf pack surroundings. Modeling simulation offer cost-effective tools designing strategies mitigate thermal runaway. Accurately simulating chemical kinetics of runaway, commonly represented by systems Arrhenius-based Ordinary Differential Equations (ODEs), requires fitting kinetic parameters experimental calorimetry data, such as Accelerating Rate Calorimetry (ARC) measurements. Particle Swarm Optimization (PSO) offers promising approach directly data. Yet, created multiple Arrhenius ODEs, computational cost using brute-force searches entire parameter space simultaneously become prohibitive. This work introduces divide-and-conquer based on PSO fit N-equation ODE models ARC The proposed method achieves more accurate compared while maintaining low costs. analyzed two distinct datasets, resulting are further validated through simulations 3D oven tests, showing excellent agreement with data align... Read More

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A secondary battery with an enclosure, electrode assembly, and non-aqueous electrolyte that uses a constraint to prevent expansion and buckling of the electrode stack during cycling. The electrode assembly has opposing ends and a lateral surface. Compression members overlie the end projections, tension members overlie the lateral surface. This maintains pressure in the stacking direction exceeding the perpendicular directions. The constraint can be inside or outside the enclosure. This prevents expansion and buckling as the battery cycles and prevents short circuits.

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Battery module design with improved thermal management to prevent heat propagation between cells in high temperature conditions. The module has an elastic member between adjacent cells and a thermally expandable resin composition inside the elastic member. This resin expands at 80°C or higher to restrict heat conduction between cells when they get hot. The resin has low thermal conductivity after expansion. The elastic member can have a concave/convex pattern.

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Battery module design for electric vehicles that improves safety in the event of a battery fault or accident by allowing controlled venting of gases to prevent overpressure and thermal runaway. The module has multiple vents in the housing walls and opposing cell vents. The housing vents initially close but open to allow partial venting if pressure rises. The cell vents initially close but open to vent gases directly. This prevents pressure buildup and prevents cell rupture while allowing venting to the outside. The housing vents also have covering parts between the cell and housing that allow straight path venting.

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<title>Abstract</title> The inconsistency between power battery cells can seriously restrict the energy utilization efficiency of pack, accelerate aging batteries, and even significantly increase risk thermal runaway. Aiming at this inconsistency, an active equilibrium scheme combining dynamic programming (DP) model predictive control (MPC) is proposed. Firstly, topology circuit bidirectional flyback transformer with rapid equalization speed built, then a system prediction established through MPC to achieve rolling optimization. Finally, using DP solve cost function in conditional scenarios obtain global optimal current time, used predict state changes multiple sampling periods online correction balanced current. algorithm improves overall reduces loss while considering charging discharging equalizer ensure consistent convergence each individual SOC. Simulation experimental results show that strategy quickly effectively correct lithium packs under various conditions, thereby greatly improving balance pack.

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Electrochemical cells with interlayers between the anode and cathode to prevent dendrite growth and mitigate safety issues like short circuiting and thermal runaway. The interlayer has a thickness that increases towards the cathode end. If a dendrite grows into the interlayer, it can be detected by monitoring the voltage potential. A battery management system can then discharge the cell and use the remaining energy to power other devices, removing cell energy to create a safe condition. The interlayer voltage can also be actively changed to stop dendrite growth or dissolve it.

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A secondary battery with improved thermal management to prevent overheating and extend battery life. The battery has a unique sheath design with a thick metal layer making up 50-70% of the total sheath thickness. The metal layer provides high thermal conductivity to efficiently dissipate heat generated during charging and discharging. This reduces the internal battery temperature without adding bulk. The remaining sheath thickness is non-metal insulation layers.

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Liquid immersion cooling (LIC) system for battery packs that uses stacked perforated separator plates between cell rows to distribute coolant fluid vertically upward between the cells. The separator plates have interconnected coolant channels with angled grooves on one plate aligned with opposite angled grooves on the other plate. This zigzag channel pattern creates a pressure differential that forces coolant to flow vertically between the cells. The perforated plates with angled channels stacked between cell rows improve LIC cooling by distributing the coolant fluid over and between the cells.

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Lithium battery with improved safety against short circuits and fire hazards. The battery uses thin metallized surface composite current collectors, high shrinkage rate separators, and materials that become nonconductive upon exposure to high temperatures. This internal fuse mechanism prevents undesirable high temperature results from short circuits. The thin current collectors stop conducting at the point of contact of an exposed short circuit. This allows for a safe discharge pathway during short circuits that prevents rapid discharge and high temperatures. The high shrinkage rate separators prevent shrinkage that could increase short circuit area. The nonconductive materials become nonconductive at high temperatures to further prevent high temperature issues.

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Lithium battery design that prevents thermal runaway and fires by using thin, low-resistance current collectors that short circuit and oxidize during high current events. The collectors are made with thin polymer substrates coated in conductive materials. The collectors have thicknesses below 20 microns and resistances below 1 ohm/square. When shorted, the thin collectors oxidize or degrade quickly, stopping the current flow before separator or cell damage. This internal fuse mechanism prevents runaway heating and fires compared to thicker, stable collectors.

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Despite the commercial success of lithium-ion batteries (LIBs), risk thermal runaway, which can lead to dangerous fires, has become more concerning as LIB usage increases. Research focused on understanding causes runaway and how prevent or detect it. Additionally, novel runaway-resistant materials are being researched, different methods constructing LIBs that better isolate it from propagating. However, field firefighters using hundreds thousands liters water control large emergencies, highlighting need merge research with practical observations. To study battery fire, this utilized a temperature abuse method increase investigated whether be suppressed by applying external cooling during heating. The used were pouch-type ones subjected high states charge (SOC), primed increase. A spray was then devised tested reduce temperature. Results showed that, without cooling, fire occurred every time abuse. successfully prevented runaway. This observation shows reducer is effective than suppressant, substantially improve performance public safety.

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