Battery University

BU-304b: Making Lithium-ion Safe

Learn all sides to make lithium-ion safe

Battery packs using Li-ion require a mandatory protection circuit to assure safety under (almost) all circumstances. Governed by IEC 62133, the safety of Li-ion cell or
packs begins by including some or all of the following safeguards.

1. Built-in PTC (positive temperature coefficient) protects against current surges.

2. CID (circuit interrupt device) opens the circuit at a cell pressure of 1,000kPa (145psi).
3. Safety vent releases gases on excessive pressure buildup at 3,000kPa (450psi).
4. Separator inhibits ion-flow by melting process when exceeding a certain temperature threshold.
(See BU-306: What is the Function of the Separator?)

The PTC and CID work well in a smaller 2- or 3-cell pack with serial and parallel configuration, however, these safety devices are often omitted in larger multi-cell
batteries, such as those for power tools, because the shutdown can occur in a cascade format. (See BU-302: Series and Parallel Battery Configurations) While some
cells may go offline early, the load current causes excess current on the remaining cells. Such overload condition could lead to a thermal runaway before the remaining
safety devices activate.

In addition to internal cell safeguards, an external electronic protection circuit prevents any cell from exceeding 4.30V on charge. In addition, a fuse cuts the current if the
skin temperature of any cell approaches 90°C (194°F). To prevent the battery from over-discharging, a control circuit cuts off the current path at about 2.20V/cell.

Each cell in a string needs independent voltage monitoring. The higher the cell count, the more complex the protection circuit becomes. Four cells in series had been the
practical limit for consumer applications. Today, off-the-shelf chips also accommodate 5–7, 7–10 and 13 cells in series. For specialty applications, such as the hybrid or
electric vehicle delivering several hundred volts, specialty protection circuits are made. Monitoring two or more cells in parallel to get higher current is less critical than
controlling the voltage in a string configuration.

Protection circuits can only shield abuse from the outside, such as an electrical short or faulty charger. If, however, a defect occurs within the cell, such as a
contamination of microscopic metal particles, the external protection circuit has little effect and cannot arrest the reaction. Reinforced and self-healing separators are
being developed for cells used in electric powertrains, but this makes the batteries large and expensive.

Li-ion commonly discharges to 3.0V/cell. The lowest permitted “low-voltage” power cut-off is 2.5V/cell. It is not advised to keep the battery at that level as self-discharge
could bring the cell to its cut-off voltage, causing the battery to go into sleep mode. Most chargers ignore Li-ion packs that have gone to sleep and a charge is no longer
possible. (See BU-808a: How to Awaken Sleeping Li-ion.)

In the ON position, the internal protection circuit has a resistance of 50–100mOhm, lower on power packs. The circuit typically consists of two switches connected in
series; one is responsible for the high cut-off, and the other for the low cut-off. Larger packs need a more careful design than a smaller battery, and single cell packs for
mobile phones and tablets get away with a voltage and current limit in addition to some intrinsic cell protection. (See BU-802a: How does Rising Internal Resistance
affect Performance?)

Some low-cost consumer chargers may rely solely on the battery’s protection circuit to terminate the charge. Redundancy is paramount for safety, and unknowingly to the
buyer, low-cost consumer chargers may be offered that do not have properly functioning charge algorithms. This could be a vehicular charger for a mobile phone or an e-
cigarette.

A further concern arises if static electricity has destroyed the battery’s protection circuit. A shorted solid-state switch is permanently fused in the ON position without the
user knowing. A battery with a faulty protection circuit functions normally but it fails to provide protection. The cell voltage could rise above a safe level and overcharge
the battery. Heat buildup and bulging are early signs of malfunction, but some batteries explode without warning.

Low prices make products from Asia attractive, but safety standards my not be equal to those in branded products. A wise shopper spends a little more money and buys
recognized brands. (See BU-809a: What Everyone Should Know about Aftermarket Batteries.)

Figure 1 shows batteries in equipment that disintegrated in a passenger aircraft before takeoff.
Figure 1: Li-ion exploded in cargo bay of an passenger aircraft
Mishap by air traveler who checked in Li-ion batteries undeclared that exploded before take-off. Shipping of
lithium-based batteries is regulated under UN 38.3.

Source: The Daily Telegraph;

Sydney 23C-34C

Manufacturers of lithium-ion batteries do not mention the word “explosion” but refer to “venting with flame” or “rapid disassembly.” Although seen as a slower and more
controlled process than explosion, venting with flame or rapid disassembly can nevertheless be violent and inflict injury to those in close proximity.

Simple Guidelines for Using Lithium-ion Batteries

Exercise caution when handling and testing lithium-ion batteries.
Do not short-circuit, overcharge, crush, drop, mutilate, penetrate with foreign objects, apply reverse polarity, expose to high temperature or disassemble packs
and cells.
Use only lithium-ion cells with a designated protection circuit and approved charger.
Discontinue using the battery and/or charger if the pack temperature rises more than 10ºC (18ºF) on a regular charge.
The electrolyte is highly flammable and battery rupture can cause physical injury.
Use a foam extinguisher, CO2, dry chemical, powdered graphite, copper powder or soda (sodium carbonate) to extinguish a lithium-ion fire. Only pour water to
prevent the fire from spreading.
If the fire of a burning lithium-ion battery cannot be extinguished, allow the pack to burn out on its own in a controlled and safe manner.

Last Updated 2017-08-10

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Basics You Should Know

Introduction
BU-001: Sharing Battery Knowledge
BU-002: Introduction
BU-003: Dedication
Crash Course on Batteries
BU-101: When Was the Battery Invented?
BU-102: Early Innovators
BU-103: Global Battery Markets
BU-103a: Battery Breakthroughs: Myth or Fact?
BU-104: Getting to Know the Battery
BU-104a: Comparing the Battery with Other Power Sources
BU-104b: Battery Building Blocks
BU-104c: The Octagon Battery – What makes a Battery a Battery
BU-105: Battery Definitions and what they mean
BU-106: Advantages of Primary Batteries
BU-106a: Choices of Primary Batteries
BU-107: Comparison Table of Secondary Batteries
Battery Types
BU-201: How does the Lead Acid Battery Work?
BU-201a: Absorbent Glass Mat (AGM)
BU-201b: Gel Lead Acid Battery
BU-202: New Lead Acid Systems
BU-203: Nickel-based Batteries
BU-204: How do Lithium Batteries Work?
BU-205: Types of Lithium-ion
BU-206: Lithium-polymer: Substance or Hype?
BU-208: Cycling Performance
BU-209: How does a Supercapacitor Work?