Advanced Multi-Cell Housing Designs to Prevent Thermal Runaway Propagation in Lithium-Ion Batteries

Fire and deflagration that might occur in high-energy content/high-power lithium ion (Li-ion) batteries are due to propagation of thermal runaway (TR) from just a single failing “trigger” cell to the remaining fully-functional cells. Here we describe iterative housing designs of a multi-cell Li-ion battery module with the goal of preventing cell-to-cell TR propagation from a trigger cell to the remaining cells in the module. After series of experimental tests and iterations, we demonstrate a battery module, containing eight fully charged 18650 cells connected in series, that prevents TR propagation from one externally-heated trigger cell. We demonstrate further that even after TR of an individual cell in that module, all remaining cells continue to maintain nameplate cell voltage and cell capacity after the event.