The advantages of lithium batteries and lithium-ion cells do not come entirely without drawbacks, because the physical structure and especially the high energy density make lithium batteries a potential hazard when handled or stored incorrectly. From burning smartphone batteries, over explosive e-bike batteries to the biggest problems, once the lithium-ion batteries catch fire, extinguishing batteries of electric cars, there are countless reports in the press about situations in which lithium-ion batteries have become a danger.
When does a lithium battery become a source of danger?
Lithium batteries and lithium-ion cells are not inherently dangerous when in good condition. Battery development has progressed to the point where the vast majority of batteries can be used safely and trouble-free without posing a danger. In addition, modern battery management systems ensure that, especially with high-powered batteries, an additional safety mechanism is built in. Nevertheless, even with these extensive safety measures, it cannot be completely excluded that lithium batteries may develop from a useful everyday helper into a source of danger.
Three causes / situations are decisive
Typically there are three causes or situations in which a harmless lithium battery becomes a danger to the environment. During charging, especially fast charging, the batteries are heavily stressed; with improper storage or improper transport, lithium batteries can become a problem. Also, if the cells have mechanical damage, which is often caused by an external force (accident with an electric car, dropping an e-bike battery, etc.).
Mechanical damage is a source of danger
Mechanical damage caused by physical impact from shocks, falls, etc., is among the most common reasons why a harmless lithium-ion battery becomes a potential danger. The possible hazard lies in the construction of a lithium battery. The cathode and anode layers inside a Li-ion battery are separated by an extremely thin layer, so damage to this inner layer can lead to short circuits and, therefore, uncontrolled energy discharges.
Damage to the separator layer is usually the cause
These micro-damages to the separator do not directly lead to the battery fire or, for example, to the explosion of an e-bike battery. However, they can be associated with higher temperature during (fast) charging and, time-delayed, become the cause of greater hazards that can ultimately lead to fire or explosion . Accordingly, lithium batteries that show mechanical damage, deformations, etc., should absolutely not be used or charged, but should be safely taken to an appropriate disposal facility and stored as safely as possible in the meantime.
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Mechanical damage
Mechanical damage to lithium batteries can lead to a short circuit and, subsequently, to a thermal runaway. These damages can be caused by impacts, blows, or intrusion of foreign objects. If the separator film between the electrodes is damaged, an internal short circuit can occur, leading to overheating of the battery.
Poor battery management system
A battery management system (BMS) is responsible for monitoring and controlling lithium batteries. A poor or faulty BMS can lead to overcharging, deep discharge, or overheating of the batteries. These states can reduce the life, performance, or in the worst case lead to thermal runaway.
Manufacturing defect
Defects in the production of lithium batteries, such as impurities in materials, voids in the separator film, or improper assembly, can lead to internal short circuits and other problems affecting safety and performance of the batteries.
Electrolyte leakage
A leak in the electrolyte can cause it to react with ambient air, triggering a chemical reaction. This can lead to potentially flammable or toxic gases, which can cause fires or health hazards.
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Wrong transportation
During the transport of lithium batteries, mechanical damage, overheating, or other hazards can occur if they are not properly packaged and protected. Impacts, falls, or moisture intrusion can compromise battery safety. Details on this point are elaborated further below.
Improper storage
Improper storage conditions, such as high temperatures, humidity, or direct sunlight, can affect the performance and safety of lithium batteries. Increased ambient temperature can cause the electrolyte to age faster and affect the cell chemistry, increasing the risk of thermal runaway. Details on this point are also provided below.
Wrong charging
Charging lithium batteries with unsuitable chargers or at wrong voltages and currents can lead to overcharging or overheating. This can shorten the battery life or, in the worst case, lead to a fire or an explosion. Details on this point are elaborated further below.
Damage or modification of devices
If electronic devices containing lithium batteries are damaged, improperly repaired, or modified, this can compromise the safety of the battery. Improper handling of the batteries, such as puncturing or removing the protection circuit, can lead to a short circuit or other hazards.
Use under extreme conditions
Using lithium batteries under extreme environmental conditions, such as very high or very low temperatures, can affect the chemical stability of the cells. This can increase the risk of thermal runaway or shorten the life of the batteries.
General hazards when (fast) charging lithium-ion batteries
Charging lithium batteries always accompanies a rise in temperature inside the battery, so that this period is always critical. Incorrect charging of lithium batteries (e.g., overcharging or using unsuitable chargers) can lead to hazard development and batteries can heat up so much that fires or even battery explosions may occur.
Only intact batteries charge safely – best in a safe environment
Generally, intact lithium batteries, charged with the correct devices and properly, do not pose an increased danger. However, you cannot always tell from the outside whether a lithium battery is completely intact. Accordingly, it is recommended to always charge lithium-ion batteries and lithium batteries in appropriately secure environments.
Improper transport and storage of lithium batteries
Improper storage of lithium batteries or improper transport can cause damage to the cells, which can then become a source of danger during charging or in other situations as described above. Improper storage and incorrect transport are potential problem causes throughout the entire life cycle. Whether at the manufacturer, wholesale, intermediate or retail level, or storage by the user or later disposal — the correct storage of lithium batteries and Li-ion batteries is of great importance. The same applies to transport between the different stages of the life cycle.
Examples of improper storage
Examples illustrate improper storage of lithium batteries. Thus, lithium batteries should be stored within a specific temperature window and especially protected from direct sunlight. If a lithium battery is stored in direct sun, the cells can quickly heat up to 50°C or more, which can damage the cells. This greatly increases the fire risk of already defective cells (e.g., due to minimal separator damage). Also moisture or extreme cold can damage lithium batteries, so this should be avoided. In everyday use, therefore, all used batteries should be stored securely. The Zarges Akku-Safe or, for example, Lio Guard boxes from Genius are ideal storage containers for private use to store e-bike batteries, power tools, or model building equipment properly.
How can one best protect oneself from the risks?
Lithium-ion batteries are not inherently dangerous, but a valuable enrichment of daily life. With some basic measures, you can minimize the risk or danger posed by lithium-ion batteries. The following are the most important factors to use lithium-ion batteries safely in everyday life:
Use of qualitatively high-quality batteries and components
To minimize the risk of problems and hazards, high-quality lithium batteries and components such as battery management systems and protection circuits should be used. Quality products are generally better manufactured and have stricter safety standards. When purchasing batteries / cells or the devices in which they are installed, pay attention to appropriate standards.
Proper transport and storage
Ensure that lithium batteries are properly packaged and protected during transport and storage. Avoid extreme temperatures, direct sunlight, and moisture. Follow the manufacturer’s instructions and the authorities' guidelines. Our assortment also includes everything needed to safely store and transport batteries.
Use of appropriate charging devices
Charge lithium batteries only with the chargers recommended or compatible with the manufacturer. Ensure that the charging voltage and current conform to the battery specifications. Changing the charger can lead to overcharging, uncontrolled heat development, damage to the cells and to the battery management system.
Regular inspection and maintenance of the batteries
Regularly check the condition of your lithium batteries and devices to detect possible problems early. Look for signs of damage such as deformations, cracks, leakage, or unusual odors. If you notice damage or malfunctions, replace the battery immediately or seek professional help.
Caution in handling and use of devices
Be careful when handling and using devices that contain lithium batteries. Avoid impacts, shocks, or intrusion of foreign objects into the device. Do not perform improper repairs or modifications that could affect battery safety. The manufacturer’s accompanying manual generally provides all necessary information and notes on handling, use and care of the battery-powered devices; errors and problems should also be addressed in the manual.
Consider environmental conditions
Use lithium batteries only under the environmental conditions recommended by the manufacturer. Avoid extreme temperatures, high humidity, or direct sunlight to ensure chemical stability and safety of the batteries and to prevent damage to cells or the separator layer.
Disposal of old batteries / spent batteries
Sooner or later even the best Li-ion batteries / cells reach the end of their life cycle and the devices or the contained batteries must be disposed of. Disposal in regular household waste is usually not only prohibited but also carries significant hazards. Dispose of old or defective lithium batteries in accordance with local regulations and the manufacturer’s or retailer’s recommendations where you purchased the device. Improperly disposed of batteries can pose an environmental hazard and in some cases even cause fires or explosions.
Training and information
Meticulous prevention can avoid many risks and hazards associated with Li-ion batteries. Inform yourself about the properties and potential hazards of lithium batteries. Share this knowledge with family members, colleagues, or employees to raise awareness of proper handling and use of lithium batteries.
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