Development of Plug-in Hybrid Electric Vehicles (PHEVs) has recently become a high national priority because of their potential to enable significantly reduced petroleum consumption by the domestic transportation sector in the relatively near term. Lithium-ion (Li-ion) batteries are a critical enabling technology for PHEVs. Among battery technologies with suitable operating characteristics for use in vehicles, Li-ion batteries offer the best combination of energy, power, life and cost. Consequently, worldwide, leading corporations and government agencies are supporting the development of Li-ion batteries for PHEVs, as well as the full spectrum of vehicular applications ranging from mild hybrid to all-electric. In this project, using a combination of well-defined experiments, custom designed cells and simulations, we have improved the understanding of the process by which a Li-ion cell that develops an internal short progresses to thermal runaway. Using a validated model for thermal runaway, we have explored the influence of environmental factors and cell design on the propensity for thermal runaway in full-sized PHEV cells. We have also gained important perspectives about internal short development and progression
specifically that initial internal shorts may be augmented by secondary shorts related to separator melting. Even though the nature of these shorts is very stochastic, we have shown the critical and insufficiently appreciated role of heat transfer in influencing whether a developing internal short results in a thermal runaway. This work should lead to enhanced perspectives on separator design, the role of active materials and especially cathode materials with respect to safety and the design of automotive cooling systems to enhance battery safety in PHEVs.