Implementing expansion force-based early warning in LiFePO4 batteries with various states of charge under thermal abuse scenarios

The characteristics of thermal runaway in batteries exhibit significant differences depending on their states of charge (SOCs), posing considerable challenges in accurate and timely warning for thermal runaway accidents. This paper conducts an experimental investigation into the external expansion force, voltage, and temperature behaviours of batteries under different SOCs under thermal abuse scenarios. The expansion force signal was found first to exhibit abnormal characteristics (with an indicator value of 5 N/s), offering an earlier warning signal >642 s prior to thermal runaway, when the battery back temperature is merely approximately 318.15 K. To analyse the main causes of abnormal expansion, ultrasonic nondestructive tests were performed and suggested that a higher SOC intensify the side reactions and cause gas generation inside batteries. Notably, compared to normal-charged batteries (0% ≤ SOC ≤ 100%), over-charged batteries (SOC > 100%) are more sensitive to expansion force than normal-charged batteries. Furthermore, compared with voltage and temperature signals, the early warning time of the expansion force rises with the increase in the SOC of an overcharged battery, in contrast to normal-charged batteries. Finally, a novel hazard classification safety warning strategy for battery failure is effectively proposed. These novel findings hold substantial practical implications for creating more accurate early warning systems for battery thermal runaway, enhancing the safe and reliable operation of battery systems.