🔋 Dynamic Ejection Phenomenon and Pressure-Driven Velocity Modeling in Thermal Runaway of High-Capacity NCM523 Lithium-Ion Batteries

Advancing Safety Design and Fire Accident Investigation

Lithium-ion batteries power modern life — from electric vehicles 🚗 to grid storage systems ⚡ and portable electronics 📱. Among them, NCM523 (Nickel-Cobalt-Manganese 5-2-3) batteries are widely used due to their high energy density and performance balance. However, as capacity increases, so does the risk of thermal runaway, a hazardous failure event that can trigger fires, explosions, and high-velocity material ejection.

Understanding the dynamic ejection phenomenon and modeling the velocity driven by internal pressure buildup are critical steps toward improving battery safety and strengthening fire accident investigations.

🔥 What is Thermal Runaway?

Thermal runaway occurs when a battery experiences an uncontrollable temperature rise due to internal chemical reactions.

Key Triggers:

• 🔌 Overcharging

• ⚡ Internal short circuits

• 🔥 External heating

• 🧪 Mechanical damage

During this process, exothermic reactions rapidly increase internal temperature and pressure, often leading to:

• Gas generation 💨

• Casing rupture 💥

• Flame jet release 🔥

• Fragment ejection 🚀

💨 The Dynamic Ejection Phenomenon

One of the most dangerous aspects of thermal runaway is the high-speed ejection of battery materials.

What Happens Internally?

As temperature rises:

• Electrolyte decomposition produces flammable gases

• Cathode materials release oxygen

• Internal pressure increases dramatically

• The casing fails at weak points

When rupture occurs, the pressurized gas and fragments are expelled at high velocity, forming directional jets that can ignite surrounding materials.

Why It Matters:

• 🔥 Increases fire spread risk

• 🏭 Threatens nearby battery modules

• 👨‍🚒 Complicates firefighting strategies

• 🔎 Provides critical clues in fire investigations

📊 Modeling Velocity Driven by Internal Pressure

To improve safety, researchers develop pressure-driven velocity models that predict:

• Peak internal pressure 📈

• Rupture timing ⏱️

• Jet velocity and direction 🌪️

• Energy release rate 💣

Core Modeling Factors:

• Gas generation rate

• Cell volume and geometry

• Vent size and rupture mechanics

• Thermochemical reaction kinetics

By applying fluid dynamics and thermodynamic principles, engineers can simulate:

$$Velocity\propto \sqrt{\frac{2P}{\mathrm{\rho }}}$$

Where:

• P = Internal pressure

• ρ = Gas density

These models help predict how forcefully materials will eject during failure.

🧪 Why NCM523 Batteries Require Special Attention

NCM523 chemistry offers:

• ⚡ High energy density

• ⚖️ Balanced thermal stability

• 🔋 Strong cycle performance

However, in high-capacity formats:

• Larger stored energy amplifies runaway severity

• More gas generation increases rupture force

• Ejection events become more destructive

Understanding this behavior is crucial for next-generation EV battery pack safety.

🛡️ Advancing Safety Design

Dynamic modeling supports improvements in:

🔹 Vent Design Optimization

Controlled venting reduces explosion risk.

🔹 Reinforced Casing Structures

Improves resistance to sudden rupture.

🔹 Thermal Barriers Between Cells

Prevents propagation across modules.

🔹 Early Detection Systems

Sensors monitor abnormal pressure or temperature rise.

These engineering solutions transform reactive safety into predictive safety.

🔎 Supporting Fire Accident Investigation

In post-incident analysis, velocity modeling helps investigators determine:

• Origin of rupture

• Direction of flame jet

• Pressure buildup sequence

• Whether failure was internal or externally triggered

This improves:

• 🔍 Root cause analysis

• ⚖️ Legal and insurance assessments

• 🏭 Manufacturing accountability

• 🔋 Product redesign strategies

🌍 Future Research Directions

Emerging research focuses on:

• AI-driven thermal runaway prediction 🤖

• Real-time pressure sensing technology 📡

• Safer electrolyte formulations 🧴

• Solid-state battery alternatives 🔬

The ultimate goal: High energy density without compromising safety.

🏁 Conclusion

The dynamic ejection phenomenon in high-capacity NCM523 lithium-ion batteries represents one of the most critical challenges in modern battery safety. By modeling velocity driven by internal pressure during thermal runaway, engineers and investigators gain powerful tools to:

• 🔋 Improve battery pack design

• 🔥 Reduce fire propagation risk

• 🔎 Strengthen forensic analysis

• 🚗 Enhance electric vehicle safety

As energy storage systems continue to expand globally, integrating pressure-driven modeling with advanced safety engineering will be essential for preventing catastrophic battery failures and advancing safer energy technologies.

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