Lithium-Ion Battery Venting: Early Detection for Improved Safety

The physics of Cell Venting Failures and means of detection

Understanding and mitigating lithium-ion battery venting is critical for ensuring safety and reliability in electric vehicles (EVs) and energy storage systems (ESS). Venting events don’t just release gas — they create plasma, arc flash risk, and potential thermal events.

 

Download the presentation: “The Physics of Cell Venting Failures & Detection Strategies.”
 

Gain deep insight into the physics of lithium-ion battery venting, the dangers of battery off-gassing, and how early gas detection can prevent catastrophic failure.

What you’ll learn:

  • How venting releases flammable gases (H₂, CO, VOCs) far above explosive limits
  • The physics of plasma ejection, particulate discharge, and ignition
  • Why ionized gases invalidate IEC 60664 insulation standards post-vent
  • The role of battery gas sensor technology in detecting failures within seconds
  • Design strategies to isolate high-voltage components and direct gas flows
  • Validation testing that proves sensor placement inside the pack airspace has minimal impact on detection speed

Understanding and mitigating lithium-ion battery venting is critical for ensuring safety and reliability in electric vehicles (EVs) and energy storage systems (ESS). Venting events don’t just release gas — they create plasma, arc flash risk, and potential thermal events.

Download your copy of the presentation today! Fill out the form on this page to gain immediate access.

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Why Lithium-Ion Battery Venting Demands a Smarter Safety Strategy


Cell venting detection is no longer a “nice-to-have” — it’s a must-have. When a lithium-ion cell vents, temperatures can exceed 1000°C and plasma can conduct across gaps once considered safe. These events have triggered arc flashes, busbar vaporization, and gas explosions in real-world tests.

The presentation outlines:

  • Why voltage and pressure sensors often miss the earliest signs of failure
  • How early detection of battery failure using gas sensors provides up to 2 minutes of lead time
  • The dangers of vented auto battery gas mixing with HV systems, creating arc discharge potential
  • Sensor data that supports regulatory and design decisions


 

What You’ll Gain from This Presentation

An in-depth understanding of lithium-ion battery venting and detection is crucial for engineers, safety professionals, and system designers. This presentation delves into:​

  • Detailed gas release chemistry during cell venting
  • Thermal energy thresholds for ignition
  • Validation of gas sensor performance inside real EV battery packs
  • Comparison of detection technologies (H₂, CO₂, pressure, temperature)
  • Integration-ready platforms: REDTR and RedCAN

 

Take the Next Step Toward Safer Battery Systems

Understand how gas sensor technology and cell venting insights are shaping the next generation of lithium-ion battery safety.

Fill out the form above to grab your copy!