The main safety issue pertaining to operating lithium-ion batteries (LIBs) relates to their sensitivity to thermal runaway. This complex multiphysics phenomenon was observed in two commercial 18650 Ni-rich LIBs, namely a Panasonic NCR GA and a LG HG2, which were based on $Li\left(N{i}_{0.8}C{o}_{0.15}A{l}_{0.05}\right)O_2$ (NCA) and $Li\left(N{i}_{0.8}M{n}_{0.1}C{o}_{0.1}\right)O_2$ (NMC811), respectively, for positive electrodes, in combination with graphite-SiO_x composite negative electrodes. At pristine state, the batteries were charged to different levels of state of charge (SOC) (100% and 50%) and were investigated through thermal abuse tests in quasi-adiabatic conditions of accelerating rate calorimetry (ARC). The results confirmed the proposed complete thermal runaway of exothermic chain reactions. The different factors impacting the thermal runaway kinetics were also studied by considering the intertwined impacts of SOC and the related properties of these highly reactive Ni-rich technologies. All tested cells started their accelerated thermal runaway stage at the same self-heating temperature rate of ~48 °C/min. Regardless of technology, cells at reduced SOC are less reactive. Regardless of SOC levels, the Panasonic NCR GA battery technology had a wider safe region than that of the LG HG2 battery. This technology also delayed the hard internal short circuit and shifted the final venting to a higher temperature. However, above this critical temperature, it exhibited the most severe irreversible self-heating stage, with the highest self-heating temperature rate over the longest duration.

After an introductory reminder of safety concerns pertaining to early rechargeable battery technologies, this review discusses current understandings and challenges of advanced sodium-ion batteries. Sodium-ion technology is now being marketed by industrial promoters who are advocating its workable capacity, as well as its use of readily accessible and cheaper key cell components. Often claimed to be safer than lithium-ion cells, currently only limited scientifically sound safety assessments of sodium-ion cells have been performed. However, the predicted sodium-ion development roadmap reveals that significant variants of sodium-ion batteries have entered or will potentially enter the market soon. With recent experiences of lithium-ion battery failures, sodium-ion battery safety management will constitute a key aspect of successful market penetration. As such, this review discusses the safety issues of sodium-ion batteries, presenting a twofold innovative perspective: (i) in terms of comparison with the parent lithium-ion technology making use of the same working principle and similar flammable non-aqueous solvent basis, and (ii) anticipating the arrival of innovative sub-chemistries at least partially inspired from successive generations of lithium-ion cells. The authors hope that the analysis provided will assist concerned stakeholders in the quest for safe marketing of sodium-ion batteries.

Solvent-free (SF) manufacturing of Lithium-ion battery (LIB) electrodes is safer and more environmentally friendly than the traditional slurry casting approach. However, as a young technique, SF manufacturing is under development of its pathways and operation conditions. In different SF processes reported in literature, extrusion is a common step. A detailed model of this process would be extremely computationally demanding. This work proposes a novel simplified discrete element model at the mesoscopic scale for the extrusion during SF manufacturing of LIB electrodes. In addition to active material particles, we consider fluid-like solid particles to approximate the molten polymer and the carbon additive phases. The formulation and other process parameters are taken from our experimental facility that uses extrusion to fabricate filaments for 3D printing of LIB cells. The simulations are carried out in a conical twin-screw extruder. Our approach allows to obtain representative electrode microstructures after extrusion, where electrical conductivity, ionic effective diffusivity, tortuosity factor and porosity are calculated. The model is a proof of concept that is employed to investigate the influence of the extruder speed and the cohesion level on the resulting electrode properties.

After an introductory reminder of safety concerns pertaining to early rechargeable battery technologies, this review discusses current understandings and challenges of sodium-ion batteries. Sodium-ion technology is now being marketed by industrial promoters who are advocating its workable capacity, use of readily accessible and cheaper key cell components. Often claimed to be safer than lithium-ion cells, currently only limited scientific-sound safety assessment of sodium-ion cells has been performed. However, the predicted sodium-ion development roadmap reveals that significant variants of sodium-ion batteries will potentially enter the market in the near future. With recent experiences of lithium-ion battery failures, sodium-ion battery safety management will constitute a key aspect of successful market penetration. As such this review discusses the safety issues of sodium-ion batteries presenting a twofold innovative perspective: i) in terms of comparison with the parent lithium-ion technology making use of the same working principle and similar flammable non-aqueous solvent basis and ii) anticipating the arrival of innovative sub-chemistries at least partially inspired from successive generations of lithium-ion cells. The authors do hope that the analysis provided will assist the concerned stakeholders in the quest for safe marketing of sodium-ion batteries.