Advancements in lithium-ion battery materials for thermal runaway prevention

Lithium-ion (Li-ion) batteries are highly preferred choice for electric vehicles due to their high energy and power densities, but their performance is highly sensitive to temperature fluctuations from charging–discharging cycles and ambient conditions, which can trigger thermal runaway (TR). Effective thermal management is crucial and involves both external cooling and internal strategies. Advances in electrode materials enhance capacity, rate capability, and operating voltage, allowing more compact, efficient packs while remaining cost-effective. Safety depends on material design, electrolyte stability, and intrinsic resistance to TR. The review details current and developmental work on novel materials for LIBs to mitigate thermal runaway. Li-ion chemistries vary in thermal stability. Commercial 18,650 LiCoO₂ cells typically trigger TR near ~148 °C, while Ni-rich NCM cells enter TR at 160–170 °C. LiFePO₄ (LFP) pouch and prismatic cells tolerate >200 °C even at high states of charge. TR severity also differs: LFP releases ~200–400 J g −1 , whereas Ni-rich NCM releases 800–1500 J g −1 along with >250 mL g −1 of gas. This highlights a safety–performance trade-off: LFP provides superior thermal tolerance but lower energy density, whereas Ni-rich cathodes offer higher energy at reduced abuse resistance. Electrolyte composition strongly affects TR. Flame-retardant liquid electrolytes reduce flammability but may lower ionic conductivity. Solid polymer and hybrid electrolytes improve safety by resisting ignition and suppressing dendrites, though interfacial and manufacturing challenges remain. Continued advances in materials, safer electrolytes, and battery-management systems are vital for wider EV adoption and alignment with the UN's Sustainable Development Goals and global clean-energy targets. • Brief details of Lithium-ion batteries. • Mechanism and brief details of thermal runaway in Lithium-ion batteries • Recent works on materials used for cathode, anode, electrolyte and separators • Role of materials in the mitigation of thermal runaway and thermal runaway propagation models • Summary of recent works on Lithium-Ion Battery Materials and commercial aspects