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2.2 Catastrophic Failure
Although extremely rare, all lithium batteries are capable of catastrophic failure if mishandled or treated.
The following are guidelines for a battery pack failure. Great caution needs to be exercised during a
catastrophic battery failure. As soon as a problem is detected (battery is hissing, you smell a burning
smell, it is billowing smoke etc), take battery system or bike outside immediately, away from all
structures and people, preferably on concrete (like a driveway). Observe the battery pack from a safe
distance to see if it is a pertinent problem that needs to be addressed immediately. Monitor the battery pack
until the cells drop below critical temperature and start to cool off. Contact local authorities if necessary!
2.3 Battery Safety (In Depth)
Main reasons a battery pack will fail:
- Short-circuit
- Charging
- Forced over-discharge
- Excessive heat or incineration
- Crush, puncture, or disassembly
While we have designed our cells and batteries to be tolerant of adverse conditions, these very active
chemical systems have limitations. Certain hazards are associated with exposure to heat and its subsequent
effects on sealed cells. These hazards include the potential for cell venting, explosion, and/or fires. The
initial source of heat can be external (welding, soldering, etc.) or internal such as heating caused by short
circuiting, excessive running currents for prolonged periods of time, forced over-discharge, charging, or
excessive mechanical abuse. Specifically, mechanical abuse in the form of excessive shock or vibration can
result in case deformation, crushing, and damage to the electrode materials.
Not guarding against these conditions may result in a hot cell or a battery pack that could vent or explode.
The intent of this section is to provide a general knowledge of how to handle cells and batteries that have
been subject to these adverse conditions. This document will focus on the following:
- Hot cells
- Leaking or venting cells
- Cells that have exploded
- Fires involving lithium batteries
The guidelines in this document are minimum recommendations.
Only trained and equipped emergency responders shall be allowed to respond to a vented cell incident.
Consult federal, state, and local regulations for emergency response regulations.
Hot Cells
A hot cell is a condition that arises due to a short circuit of the cell or battery, either internal or external. The
cell/battery temperature rises as the event continues which can lead to the cell reaching critical temperature
and the potential to vent or explode.
Vented Cells
It is unlikely that any lithium battery would explode. These events are rare and are usually the
result of an abusive condition or misuse that raises the cell temperature above its critical point.
In the event of a lithium battery explosion, a room can quickly fill with a dense white smoke
that can cause severe irritation to the respiratory tract, eyes, and skin. Precaution must be
taken to limit exposure to these fumes.