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UL and the UL logo are trademarks of UL LLC © 2013
TEST METHOD FOR SIMULATING
INTERNAL SHORT CIRCUITS IN LITHIUM
ION CELLS Alvin Wu
Mahmood Tabaddor, PhD
Carl Wang, PhD
Corporate Research
The Seventh Triennial International Fire &
Cabin Safety Research Conference
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FIELD FAILURES
Since 2006, reports of failure but not much detail
• Highly publicized failure of laptops powered by
lithium ion batteries including fire and explosion
• Reports of home fires caused by lithium-ion batteries
in devices during usage or charging
• Cargo airplane fires involving bulk transport of
lithium ion cells and NTSB investigation of
passenger 787 plane
• Electric vehicles are based on lithium ion cell
chemistries sometimes utilizing several thousands of
commercial, off the shelf (COTS) cells
• In some cases, it has been noted that defects lead to
internal short circuit (ISC) and thermal runaway
2
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CPSC Recall Data (1/2008-3/2012)
467
2,056,318
353
Number of Reported
Incidents
Quantity of Product
Recalled
Number of Incidents with
Fire/Burn Hazard
Battery can overheat posing a fire hazard
Identifying lithium-ion cells as the battery type
(compiled by UL staff)
3
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GM VOLT BATTERY INCIDENT
4
Incident: NHTSA post-crash fire (June 2011)
Cause: As a result of the crash, a stiffener damaged some batteries
and ruptured coolant system inside battery compartment
leading to short circuit.
To keep the battery operating safely, the Volt battery system “has more parts than
the rest of the car combined, including 600 seals and cooling components.”
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5
RESEARCH OBJECTIVE
Consider the need for a new test for UL 1642 to
address field failures of lithium ion cells
Focus Area: Internal Short Circuit of a Cell
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FAULT TREE ANALYSIS
6
Unsafe Operation
Lithium Ion Cell
Toxic Gases
Electrolyte Leakage
Fire/Explosion
Deflagration of
vented volatiles
Insufficient or No Energy
Unable to operate device
in a safe manner
Fuel
Vented Volatiles
from Cell
Air
Ambient Air (or
released oxygen)
Internal Ignition
source
Contact with Hot
Surface
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DEEPER INTO THE FTA
7
Fuel
Vented Volatiles
from Cell (from
Thermal Runaway)
Localized heat source
Internal Short Circuit
SOC
Sufficient State of
Charge Self-sustaining reaction
Exothermic Reactions
4 different types of ISC
Internal Defect
Breach of Separator by
Particle
External Force
Damaged Separator due
to external forces
Heat Dissipation
Inadequate cooling
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INTERNAL SHORT CIRCUIT (ISC)
8
ISC
EXTERNAL FORCE
- Crush
- Penetration
- Indentation
- Vibration
INTERNAL DEFECT
- Manufacturing
- Aging
(overcharging,
etc.)
Localized
Temperature
Increase
Exothermic
Reactions
Heat Dissipation
• Fire
• Explosive
release of
gases
• Leakage
• Cell to Cell
propagation
• ‘Safe Failure’
Thermal Runaway
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9
UL 1642 TESTING TASK GROUP
BSCI
Dell
Dupont
E-One Moli
Exponent
Ford Motor Company
IBM
ITRI
Motorola
NASA
ORNL
Panasonic
SNL
SONY
UL (chair)
CDC-NIOSH
OBJECTIVE
Help support review and
revision of an ISC test
method that might be
suitable for battery safety
standard
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REVIEW OF ISC TEST METHODS
Slow Speed
Nail Penetration
Test
ITRI
Low-Melting Point
Metal/Alloy Triggered
ISC Test
SNL/NREL
Forced ISC Test
BAJ
Pinch Test
ORNL
Indentation Induced
ISC Test
UL/NASA
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INDENTATION INDUCED ISC TEST
11
• Features of New Test Method
- Localized indentation of cell without penetration
- Controlled speed and temperature conditions
- Specified state of charge (SOC) and cycle life of cell
- Measure cell surface temperature, open circuit voltage (OCV), displacement and force of indenter along with visual observations
- Induce failure to assess performance of cell
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SAMPLE RESULTS
12
• Observed flames and smoke
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© 2011 Underwriters Laboratories Inc.
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© 2011 Underwriters Laboratories Inc.
TEMPERATURE DISTRIBUTION
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
50
60
70
80
90
100
110
120
130
140
150
0 20 40 60
Cell
OC
V (
V)
an
d
Dis
pla
ce
me
nt
(mm
)
Te
mp
era
ture
(oC
)
Test Time (sec.)
Temperature 1
Temperature 2
Temperature 3
Displacement
OCV
Temperature 1:
Closest to ISC point
Peak:
139oC at 25 sec
Temperature 3:
Farthest to ISC point
Peak:
109oC at 34 sec
Temperature 2:
Peak:
120oC at 32 sec
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SIMULATING FIELD FAILURES
15
0% SOC
50% SOC
• Localized ISC (1-2 mm radius)
• Low impedance pathway
• Depth several layers
• Maintain heat transfer pathways (do not
puncture cell)
• Location is near surface of cell
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STOBA IN 18650 CELLS
16
18650-type NMC (1950
mAh) without STOBA
additive
25˚C
18650-type NMC (2000
mAh) with STOBA
additive
25˚C
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AGING EFFECT ON SAFETY
17
Capacity deterioration
Power loss
Material degradation
Internal pressure increase
Impedance increase
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AGING EFFECTS ON ISC
New Cell
100% fails (N=3) 100 Cycle Aged Sample
1 cell pass and 1 cell fail
45oC
New Cell
100% fails (N=3) 200 Cycle Aged Sample
1 cell pass and 1 cell fail
20oC
400 Cycle Aged Sample
2 cells pass
400 Cycle Aged Sample
2 cells pass
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PRISMATIC CELLS
19
Cell expanded,
fire and spark
Cell casing was punctured
Lithium cobalt oxide, 1900 mAh, 4.25 V
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POUCH CELLS
20
Casing is punctured by indenter (load drops before OCV drop)
Lithium cobalt oxide, 2150-3800, mAh, 4.25 V
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• UL is considering safety aspects of lithium-ion cells from the single cell
to large number of cells throughout the lifecycle.
• Challenges to lithium-ion battery safety testing include:
o Access (cost) to large number of cells and/or large format batteries
o Battery technology is still evolving and there is no single
representative cell type
o Sound safety laboratory protocols for testing program especially for
many cells, modules, and packs.
CHALLENGES
21
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SUMMARY
22
At the cell level, UL is working on developing a new ISC test method
for battery safety standard (UL 1642)
• Simulates internal short circuit by creating a small localized defect
in separator
• Induce failure of the cell for cylindrical, prismatic, and pouch
• Sensitive to design changes that affect safety performance
• Method suitable for standards testing
UL is actively improving existing standards and developing new
standards building on cell safety all the way to battery system safety
• Large format focus (UL 2580, UL 2271, UL 1973)
• Revising cell requirements to address specific applications
• Verifying cell operating region
• Ensuring system maintains cell operating region
• System FMEA/Functional safety
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23
THANK YOU.