There is a high risk of battery ejection and explosion. How to safely complete the combustion test?

With the transformation of the electric vehicle (EV) industry and the global large-scale application of energy storage systems (ESS), lithium-ion batteries have become the core of modern engineering technology. However, every breakthrough in energy density is accompanied by significant safety concerns that cannot be ignored. Among the reliability tests stipulated by various international standards, the battery combustion and jetting test is the one with the highest risk level.

When a battery fails during a fire test, it does not simply catch fire; instead, it undergoes a violent thermal runaway, accompanied by the rapid ejection of molten substances and toxic gases, and even leading to an explosion. For the experimenters and manufacturers, the key challenge lies in: how to accurately assess the extreme performance of the battery in a fire situation while ensuring the safety of personnel and equipment.

As a leading enterprise in professional testing solutions, Tai'an Test offers advanced equipment and comprehensive safety standards, effectively addressing all kinds of extreme testing risks.

Why is the battery combustion test extremely dangerous?

Traditional material fire resistance tests only assess the flammability of the material, while battery combustion tests are quite different. The battery itself is an active chemical system. Under the influence of an external flame, its internal temperature rises sharply, causing the separator to melt and an internal short circuit, ultimately triggering a violent exothermic chain reaction.

1. The Rocket Effect: As the internal pressure suddenly increased, the battery shell cracked. High-pressure gas was ejected, not only causing the battery to fly out like a projectile, but also forming a directed jet of flame similar to that of a blowtorch.

2. Explosive Fragmentation: In the most extreme cases, the battery casing may even disintegrate, sending out lethal metal fragments in all directions.

3. Toxic Gas Evolution: When a lithium battery catches fire, it will release hydrogen fluoride (HF), carbon monoxide and other harmful gases. If inhaled, it can cause fatal consequences.

To address these risks, the use of specially designed battery combustion jet testing equipment is not just a suggestion, but a necessary step that is explicitly required by regulations.

Comply with global safety standards

Laboratory safety stems from compliance. Various international standards have strict regulations for the execution of combustion tests. While ensuring operational safety, they also guarantee the repeatability of test data.

• UL 1642 & UL 2580: These international standards represent the gold standard for lithium battery safety: They stipulate that the battery should be exposed to flames until it catches fire or explodes, and a stainless steel mesh cover should be placed around the sample to capture any flying fragments.

• IEC 62133: Safety requirements for portable sealed secondary batteries.

• UN 38.3: The standard for the safe transport of lithium batteries, which includes impact and fire exposure criteria.

The test equipment used in Taian's tests is strictly designed based on these international standards for engineering purposes. This ensures that your laboratory will always be in a safe and controlled state when conducting extreme tests on batteries.

How to safely contain a chemical explosion?

1. Reinforced Containment and Projectile Protection

Ordinary laboratory fume hoods are far from meeting safety requirements. The high-quality battery combustion testing machine uses a thickened stainless steel inner container and is equipped with a special aluminum protective net. This net cover is designed in accordance with UL standards and can effectively prevent high-speed splashing battery fragments and projectiles from penetrating the equipment shell, thus avoiding damage to the equipment casing.

2. Explosion-Proof Observation Windows

Engineers need to see the failure to understand it. Modern equipment uses multi-layered explosion-proof glass. This allows for high-speed photography and visual inspection without exposing the operator to the "blast zone."

3. Integrated Fire Suppression and Exhaust

Toxic smoke is the primary safety hazard. The test systems tested in Tai'an all incorporate powerful exhaust vents, which can be directly connected to the laboratory scrubbers to promptly handle harmful smoke. Moreover, in the event of an uncontrollable fire, the built-in carbon dioxide or dry powder fire suppression devices can be automatically activated, effectively protecting the equipment assets.

4. Remote Operation and Data Logging

The key to maximizing safety lies in the separation of humans and machines: Technicians can trigger the ignition and monitor temperature fluctuations through a remote control interface in the isolation room. If the combustion test data is combined with the results of the battery internal short-circuit test machine, it is possible to conduct a more in-depth analysis of the battery failure mode and construct a comprehensive safety profile.

FAQs: Common Questions in the Industry

Q1: What is the difference between a "flame retardancy test" and a "combustion test"?

Flame retardant tests typically measure the speed at which a material stops burning after the heat source is removed. In contrast, battery combustion tests are destructive tests. The core of these tests is to observe the total energy released and the physical hazards caused when the battery acts as its own fuel source.

Q2: How do you handle the "Jetting" effect in a small lab space?

The jetting phenomenon during battery combustion is unpredictable, so the test chamber must be designed with a dedicated vent. This vent enables the shock waves generated by the explosion to be discharged through a pre-set safe path (usually upwards or towards the reinforced wall), thus preventing the chamber door from being blown open.

Q3: Can thermal abuse testing replace combustion testing?

This is not the case. The thermal abuse test chamber simulates high-temperature conditions to trigger battery failure, while the combustion test uses an external flame to assess the battery's performance in the event of a fire. The two complement each other in safety certification and are both indispensable.

Q4: How do you clean the equipment after a violent explosion or combustion?

This is a crucial maintenance step. The internal components of the Tai'an testing equipment are made of easily cleanable stainless steel. After each test, carbon deposits and chemical residues must be thoroughly removed to prevent corrosion of the equipment and to maintain the accuracy of subsequent tests.

Procedural Best Practices for Lab Safety

• Pre-Test Inspection: It is necessary to ensure that there is no leakage in the gas pipeline of the burner and that the aluminum protective net is installed firmly and reliably.

• Limited Access: During the period when the equipment is being actively heated, only essential personnel are allowed to enter the laboratory and they must maintain a safe distance.

• Post-Test Quenching: After the flame is extinguished, do not open the box door immediately to prevent the battery from reigniting. Wait until the internal thermocouple indicates that the temperature has dropped to normal before opening it.

• Personal Protective Equipment (PPE): Even if equipped with a protective box, when the operators handle the test debris, they must wear fireproof suits and wear gas masks.

Conclusion: Safety is the cornerstone of innovation.

In the battery industry, a single safety incident can lead to a large-scale product recall, seriously damaging the brand's reputation. Conducting high-risk combustion tests is a necessary measure to ensure the safety and reliability of the products during user usage. 

By choosing the professional battery testing equipment from Tai'an Test, manufacturers can transform high-risk tests into controllable scientific processes. Whether it is small consumer-grade battery cells or large battery power modules, the combination of robust hardware and strict operational standards is the necessary path to achieving safety innovation.