IEC 62133-2 is changing. This presentation will summarize the changes and how manufacturers can prepare to meet the requirements without impacting product delivery. Along with managing the changes, we will discuss how IEC 62133-2 is being implemented globally to ensure cells and batteries are able to cross borders with no restrictions.

The transport rules for lithium batteries are ever-changing. There are new developments in 2020, including a new Lithium Battery Test report and new restrictions by carriers.

New combination of thin steel rings around the spin groove of 18650 cells and ceramic putty interstitial material shows great promise at mitigating the hazard of side wall breaches during thermal runaway, while yielding 1 kWh battery deck assembly that exceeds 160 Wh/kg and is capable of 3C continuous discharge. Thermal gradient between cells found to be reduced dramatically with each cell in axial contact with an oscillating heat pipe technology to enhance cycle life and obviate cell balancing. Topology trade and analyses between P-S and S-P indicates vulnerability of each to propagation of thermal runaway due to a cell internal short circuit and favors S-P. Lastly, certain thin, lightweight barriers to cell thermal runaway ejecta are shown to prevent perforation of thin aluminum sheet metal panels and new flexible gas permeable membrane vents coupled with baffles, copper mesh, and screens are shown to prevent flames from existing the battery enclosure during a single cell thermal runaway event.

While current testing is still beneficial towards obtaining useful information, it is not specific enough to generate data for technological improvements that can have a major impact on the safety of battery design. This work proposes extending these standards to obtain specific information that pertains to how pouch cell Li-ion batteries respond to penetrations using a drop hammer test with a nail.

Functional Safety is relied upon to maintain safe operating conditions for energy storage energy space, whether it be through the use of an Battery Management System, a charging station, inverters, and other control systems make correct and safe decisions. We will summarize functional safety and how it impacts these products.

As lithium-ion batteries enter the next phase of innovation, we need to factor in newer chemistries (e.g., high nickel cathodes), process changes (e.g., use of recycled materials) and larger scales of deployment (e.g., battery packs for heavy duty trucks or stationary installations) when designing quality evaluation criteria as well as management strategies. Traditional data-driven approaches often face limitations and need a critical examination in the context of battery safety.

The inclusion of sensors inside a cell offers valuable insight into electrochemical and thermal behaviour not possible from external measurement, with potential for greater understanding and extending safe operation limits particularly under higher current application. This work will detail advances in implementation at both cylindrical and pouch format, with variations between in-situ and ex-situ measurements discussed in light of accepted cell operational limits.

SafeCore is a transformative technology that acts like a fuse to prevent lithium-ion batteries from being the source of a fire or an explosion, which is typically due to three primary causes: Overcharge, internal short or external heat. SafeCore is activated by current. voltage or temperature thresholds.

It has been established that batteries using hard-bused connections are inherently unstable at high discharge rates. This paper evaluates the feasibility of using MOSFETs in the active mode to modulate the current from each battery string in a 19S4P array using Simulink and active feedback mechanisms. Discussion will include model development, results, and a path forward for experimental validation.

Leak testing is a crucial and safety-relevant aspect - whether battery cells, modules and full packs! ZELTWANGER is a pioneer in this field, with over 10 years experience, and operates as a holistic partner for premium manufacturers worldwide. Our systems have unique benefits, and cover the full spectrum from instrumentations to semi- or fully automated work stations. This presentation will explain crucial technical considerations and our industrial solutions to it.