Investigation of battery safety states based on thermal propagation and expansion analysis: Experimental studies on different packaging forms

• Thermal propagation are essential to research the safety problem of battery. • A methodology to study thermal propagation of different packaging forms batteries. • Analysis of temperature, voltage, expansion force, and explosion pressure data. • The key features of thermal propagation are summarized and evaluated. • Recommendations for battery safety warnings and fire suppression and retardation. Lithium-ion batteries are highly susceptible to thermal runaway under harsh conditions, posing significant safety risks for electric vehicles. The differences in thermal runaway propagation across battery systems with varying manufacturing methods (including packaging and internal stacking) and the study of changes in expansion force within battery modules are crucial for improving safety and developing early warning systems for battery systems. This study investigates the thermal runaway and propagation behavior of lithium-ion batteries under various conditions, focusing on state of charge (SOC), internal manufacturing processes (electrode stacking and winding), and packaging types (pouch and prismatic) through a series of novel experiments. The results show that batteries at high SOC levels are at a greater risk of thermal runaway propagation, with winding pouch cells displaying more severe runaway behavior. In contrast, prismatic cells, despite experiencing intense explosions with an equivalent force of up to 42.3 g of TNT, exhibit relatively milder propagation. Furthermore, the study incorporates heat transfer analysis during thermal runaway propagation, identifying key phenomena such as the formation of negative pressure zones before explosions and changes in expansion forces at the module level. Based on these findings, a new safety evaluation method is proposed to assess the risk, hazards, and severity of thermal runaway, offering valuable insights for enhancing battery safety management and fire prevention strategies.