How does the horizontal extrusion and needle-punching machine meet the explosion prevention and smoke exhaust requirements after battery thermal runaway?

With the global transformation of energy structure, electric vehicles and energy storage systems have witnessed explosive growth, making the safety of lithium-ion batteries increasingly crucial. High energy density is a technological trend, but how to ensure its stability has become a challenge that the industry must overcome. Compression and puncture tests are the core link of battery safety assessment， as they can realistically simulate extreme mechanical failure scenarios that lead to internal short circuits and thermal runaway.

For safety engineers and battery manufacturers, the core issue has shifted from "whether the battery catches fire" to "how the testing equipment can safely control and analyze the entire process when a fire occurs". This is precisely the core value of the horizontal extrusion and puncture integrated machine. As a core product of Tai'an Instruments, our equipment not only triggers battery failure but also remains stable in extreme heat runaway conditions, providing a controllable research environment for explosion prevention design and smoke emission control.

Why choose the horizontal structure and dual functions？

In real traffic accidents or cases of foreign objects intrusion, the battery cells and modules will suffer severe compression or be punctured by sharp objects. The horizontal compression test uses controllable hydraulic loading to deform the battery housing, causing an internal short circuit; the needle-puncture test uses a steel needle to pierce the separator, triggering an instantaneous release of chemical energy.

Compared to the vertical structure, the horizontal layout offers better stability in the testing of large-sized and heavy battery modules. It is convenient for sample loading and unloading, enables precise application of hydraulic loads along the battery axis, and can better match the laboratory ventilation system to achieve efficient collection of exhaust gases.

How to design the explosion-proof structure？

The energy released during the thermal runaway of high-capacity batteries is extremely intense. Therefore, the core of the Tai'an testing equipment lies in structural control.

1. Strengthen the structure of the box

The inner walls of the test chamber are made of high-grade corrosion-resistant SUS304 stainless steel, which not only ensures durability but also can withstand the high-temperature plasma generated by thermal runaway and corrosive chemical sprays. Special flame-retardant insulation materials are filled between the inner lining and the outer shell to ensure that the outer wall of the equipment is always at a safe touchable temperature.

2. Pressure release system

The essence of an explosion is a sudden increase in pressure. Test chambers without pressure relief designs will become high-risk pressure vessels. Our horizontal equipment is equipped with an automatic pressure sensing relief port, which has been precisely calibrated. When the pressure exceeds the critical value, it will automatically open, directing the shock wave to a safe area to ensure the safety of the laboratory and personnel.

3. Multi-layer explosion-proof inspection window

Engineers need to observe the failure process in real time to obtain first-hand data. We use a combination of multi-layer tempered glass and high-strength PC shields to ensure clear observation， while also providing bulletproof protection, effectively blocking high-speed fragments and electrolyte jetting.

Smoke exhaust and gas extraction involve several stages？

1. Positive pressure ventilation: The high-power explosion-proof fan creates a negative pressure in the box, enabling the rapid removal of smoke, thus preventing soot from obscuring the view or corroding mechanical components.

2. Filtering and Purification: The flue gas must undergo pre-treatment before being discharged. The Tai'an instrument system can integrate an external scrubber to neutralize acidic gases such as HF and filter out particulate matter.

3. Post-treatment: After the flame is extinguished, the equipment automatically introduces fresh air to remove the remaining combustible gases, ensuring the safety of the technicians when they clean up the debris.

FAQ: Common Concerns in Battery Safety Testing

Q1：What is the difference between "constant pressure" and "constant displacement" in the compression test?

The compression test can be stopped either when reaching the set pressure value or when the battery deforms by a certain percentage, in accordance with international standards such as UL 2580 and GB 38031. This machine is equipped with a high-precision pressure sensor and displacement encoder, which can accurately trigger the stop mechanism to prevent excessive damage to the test fixtures.

Q2：How can we prevent the needle from melting at high temperatures during the acupuncture experiment?

The temperature of thermal runaway can instantly exceed 1000°C. If the steel needles melt and deform prematurely, it will directly lead to the failure of the test. We use specially heat-treated high-strength alloy steel needles, which can maintain structural stiffness under extreme high temperatures and ensure a stable and consistent short-circuit path throughout the observation process.

Q3：Can the same device simultaneously test the cells (Cell) and the modules (Module)?

It is theoretically feasible, but the explosion-proof and smoke-extraction requirements will significantly increase. A single 18650 battery cell has a relatively small pressure-release energy, while a 100 kWh module experiences a huge energy release during pressure relief. We adopt a modular design, allowing us to customize the box volume and hydraulic tonnage ranging from 10kN to 500kN according to customer needs. This covers all scenarios from developing battery cell tests to verifying production modules, ensuring comprehensive application coverage.

Q4： What fire suppression systems are there in the test chamber?

Our models can be equipped with carbon dioxide (CO2), heptafluoropropane (FM-200) or water mist fire suppression systems. These systems can be automatically activated by the integrated smoke and fire sensors, or can be manually initiated by the operator.

conclusion

Taian Instruments not only focuses on equipment manufacturing, but also strives to build a strong foundation of industry safety confidence. We integrate high-strength mechanical structures, intelligent smoke gas treatment, and precise hydraulic control. Our horizontal extrusion needle-embedding integrated machine can provide core data for manufacturers, helping to create safer electric vehicles.