Lithium batteries as a source of danger

However, the advantages of lithium batteries and lithium-ion batteries are not entirely without disadvantages, as the physical structure and in particular the high energy density make lithium batteries a source of danger if handled or stored incorrectly. From burning smartphone batteries and explosive e-bike batteries to major problems extinguishing e-car batteries once they have caught fire, there are countless reports in the press of 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 batteries are not a source of danger per se when intact. Battery development has progressed to such an extent that by far the largest proportion of all rechargeable and non-rechargeable batteries can be used safely and without any problems without posing a hazard. In addition, modern battery management systems ensure that an additional safety mechanism is built into particularly powerful rechargeable batteries and batteries. Nevertheless, even with these various safety measures, it is not possible to completely rule out the possibility of lithium batteries developing from a useful everyday helper into a source of danger.

Three causes / situations are decisive

There are typically three causes or situations in which a harmless lithium battery becomes a source of danger for the environment. During charging, especially fast charging, the batteries are subjected to high stresses, and lithium batteries can become a problem if they are stored incorrectly or transported improperly. Even if the cells suffer 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 the physical impact of shocks, falls etc. is one of the most common reasons why a harmless lithium-ion battery becomes a potential source of danger. The potential danger lies in the structure of a lithium battery. the cathode and anode layers within a lithium-ion battery are separated from each other by an extremely thin layer, meaning that damage to this inner layer can lead to short circuits and thus uncontrolled energy discharges.

Damage to the separator layer is usually the cause

However, this micro-damage to the separator does not lead directly to a battery fire or, for example, to an e-bike battery exploding. However, they can, for example, be associated with an increased temperature during (fast) charging and, with a time delay, become the cause of greater dangers, which can ultimately lead to a fire or explosion. Accordingly, lithium batteries that exhibit mechanical damage, deformation, etc. should not be used, charged, etc. under any circumstances, but should be taken safely to a suitable disposal point and stored as safely as possible until then.

Overview of hazards within the battery

Mechanical damage

Mechanical damage to lithium batteries can lead to a short circuit and subsequently to a thermal runaway. This damage can be caused by shocks, impacts or the ingress of foreign bodies. If the separator foil between the electrodes is damaged, an internal short circuit can occur, causing the battery to overheat.

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 discharging or overheating of the batteries. These conditions can lead to a reduction in service life, performance or, in the worst case, thermal runaway.

Production errors

Errors in the manufacture of lithium batteries, such as impurities in the materials, defects in the separator foil or improper assembly, can lead to internal short circuits and other problems that affect the safety and performance of the batteries.

Electrolyte leakage

A leak in the electrolyte can cause it to react with the ambient air and cause a chemical reaction. This can cause potentially flammable or toxic gases to develop, which can lead to fires or health hazards.

Overview of hazards associated with incorrect handling / use

Incorrect transportation

During transportation of lithium batteries, mechanical damage, overheating or other hazards may occur if they are not properly packaged and protected. Shocks, falls or the ingress of moisture can impair the safety of the batteries. Details on this point are given below.

Improper storage

Improper storage conditions, such as high temperatures, humidity or direct sunlight, can impair the performance and safety of lithium batteries. An elevated ambient temperature can cause the electrolyte to age faster and affect the cell chemistry, leading to an increased risk of thermal runaway. Further details on this point can also be found below.

Incorrect charging

Charging lithium batteries with unsuitable chargers or at incorrect voltages and currents can lead to overcharging or overheating. This can shorten the service life of the battery or, in the worst case, lead to a fire or explosion. Details on this point are given below.

Damage to or modification of devices

If electronic devices containing lithium batteries are damaged, improperly repaired or modified, this may impair the safety of the battery. Improper handling of the batteries, such as puncturing or removing the protective circuit, can lead to a short circuit or other hazards.

Use under extreme conditions

The use of lithium batteries under extreme environmental conditions, such as very high or low temperatures, can impair the chemical stability of the cells. This can lead to an increased risk of thermal runaway or a reduced service life of the batteries.

General dangers when (fast) charging lithium-ion batteries

Charging lithium batteries is always accompanied by an increase in temperature in the battery, so this period is always critical. Improper charging of lithium batteries (e.g. overcharging or the use of unsuitable chargers) can lead to the development of hazards and cause batteries to heat up to such an extent that fires or even battery explosions can occur.

Only charge intact batteries - preferably in a safe environment

In general, however, the following applies: intact lithium batteries that are charged properly using the correct equipment do not pose any increased risk. However, it is not always possible to tell from the outside whether a lithium battery is completely intact. It is therefore recommended that lithium-ion rechargeable batteries and lithium batteries are always charged in appropriately secured environments.

Improper transportation and storage of lithium batteries

Improper storage of lithium batteries or improper transportation can lead to damage to the cells, which can then become a source of danger when charging or in other situations as described above. Improper storage and incorrect transportation are potential causes of problems throughout the entire life cycle. Whether at the manufacturer, wholesaler, distributor or retailer through to storage by the user or subsequent disposal - the correct storage of lithium batteries and Li-ion rechargeable batteries is of great importance at all points. The same applies to transportation between the individual points of the life cycle.

Examples of improper storage

Examples illustrate the improper storage of lithium batteries. Lithium batteries should be stored within a certain temperature range and protected from direct sunlight in particular. If a lithium battery is stored in direct sunlight, the cells can quickly heat up to temperatures of 50°C and more, which can damage the cells. This greatly increases the risk of fire in cells that are already defective (e.g. due to minimal separator damage). Moisture or extreme cold can also damage lithium batteries, so this should be avoided. All used batteries should therefore always be stored safely in everyday life. The Zarges battery safe or, for example, Lio Guard boxes from Genius are also ideal battery storage containers for private use to store e-bike batteries, PowerTools or, for example, model making batteries correctly.

What is the best way to protect yourself from the risks?

Lithium-ion batteries are not dangerous per se, but a valuable addition to everyday life. A few basic measures can be taken to minimize the risk or danger posed by lithium-ion batteries. The following is a list of the most important factors that can be used to safely use lithium-ion batteries in everyday life:

Use of 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. Pay attention to appropriate standards when purchasing rechargeable batteries or the devices in which they are installed.

Proper transportation and storage

Ensure that lithium batteries are properly packaged and protected during transportation and storage. Avoid extreme temperatures, direct sunlight and moisture. Follow the instructions and guidelines of the manufacturer and the relevant authorities. In our range you will also find everything you need to store and transport rechargeable batteries safely.

Use of suitable chargers

Only charge lithium batteries with the chargers recommended by the manufacturer or compatible chargers. Ensure that the charging voltage and charging current correspond to the specifications of the battery. Changing the charger can lead to overcharging, uncontrolled heat development, damage to the cells and the battery management system.

Regular inspection and maintenance of the batteries / rechargeable batteries

Regularly check the condition of your lithium batteries and devices to identify potential problems at an early stage. Look out for signs of damage, such as deformation, cracks, leakage or unusual odors. If there are signs of damage or malfunctions, you should replace the battery immediately or seek professional help.

Caution when handling and using devices

Be careful when handling and using devices that contain lithium batteries. Avoid knocks, falls or the ingress of foreign objects into the device. Do not carry out any improper repairs or modifications that could impair the safety of the battery. The manufacturer's enclosed instructions for use generally provide all the necessary information and instructions for handling, use and care of the battery-powered devices; faults and problems should also be addressed in the instructions for use.

Observing environmental conditions

Only use lithium rechargeable batteries in the environmental conditions recommended by the manufacturer. Avoid extreme temperatures, high humidity or direct sunlight to ensure the chemical stability and safety of the batteries and to prevent damage to the cells or separator layers, for example.

Disposal of old rechargeable batteries / used batteries

At some point, even the best Li-ion rechargeable batteries will reach the end of their life cycle and the devices or the rechargeable batteries they contain must be disposed of. Disposal with normal household waste is not only generally not permitted, but also poses significant risks. Dispose of old or defective lithium batteries in accordance with local regulations and the recommendations of the manufacturer and / or dealer from whom you purchased the device. Incorrectly disposed of batteries can pose an environmental hazard and in certain cases even cause fires or explosions.

Training and information

Careful prevention can avoid many risks and dangers that can arise from Li-ion batteries. Educate yourself about the characteristics and potential hazards of lithium batteries. Share this knowledge with family members, colleagues or employees to raise awareness of the correct handling and use of lithium batteries.