A new lithium-ion battery design developed in China could mark a turning point for battery safety. Unlike conventional batteries, which can burst into flames under stress, this one stays cool even when punctured with a nail.
New lithium-ion battery design resists thermal runaway
Researchers from the Chinese University of Hong Kong have engineered a battery that resists thermal runaway, a dangerous chain reaction that causes temperatures to spike and can result in fires or explosions. In typical batteries, internal failures can raise the temperature by over 500 °C. In contrast, this new design saw only a 3.5 °C increase during nail penetration tests.
The key lies in stopping thermal runaway before it starts, a problem that has long plagued lithium-ion technology used in everything from EVs to laptops.
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Researchers identified ion association as the safety trade-off
The breakthrough came when the team zeroed in on ion association in the battery’s electrolyte. In traditional batteries, lithium ions and negative ions form stable clusters. These are great for forming the solid electrolyte interphase (SEI) a layer crucial for battery longevity but also lower the temperature threshold for thermal runaway by nearly 94 °C.
That trade-off has made it difficult to boost safety without hurting long-term battery performance.
Solvent-relay strategy stabilizes battery under heat stress
To fix this, the researchers created a “solvent-relay strategy.” They formulated a new electrolyte that adapts to temperature changes. At normal temperatures, it still encourages ion association to form the SEI layer. But when the battery heats up, a compound called lithium bis(fluorosulfonyl)imide takes over. It bonds with lithium and promotes ion dissociation, breaking up harmful reactions that would normally trigger runaway heat release.
Here’s how the new design performs:
- Temperature rise after puncture: 3.5 °C (vs. 555.2 °C in conventional cells)
- Explosion risk: Eliminated in tests
- Battery cycle life: 81.9% capacity retained after 1,000 cycles
Lithium-ion battery safety could change with this approach
By combining high safety and long-term durability, this new battery design could reshape how we approach battery tech in consumer electronics and electric vehicles. While more commercial testing is needed, the early results show a practical path toward fire-resistant lithium-ion cells without compromising performance.
