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Assessing Lithium-Ion Battery Safety Under Extreme Transport Conditions: A Comparative Study of Measured and Standardised Parameters

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  • Yihan Pan

    (College of Transportation, Chongqing Jiaotong University, Chongqing 400074, China)

  • Xingliang Liu

    (College of Transportation, Chongqing Jiaotong University, Chongqing 400074, China)

  • Jinzhong Wu

    (College of Transportation, Chongqing Jiaotong University, Chongqing 400074, China
    Research Center for Hazardous Materials Storage and Transportation Safety, Chongqing Jiaotong University, Chongqing 400074, China)

  • Haocheng Zhou

    (College of Transportation, Chongqing Jiaotong University, Chongqing 400074, China)

  • Lina Zhu

    (Shanghai Institute of Chemical Industry Testing Co., Ltd., Shanghai 200062, China)

Abstract

The safety of lithium-ion batteries during transportation is critically important. However, current standards exhibit limitations, as their environmental testing parameter thresholds fail to fully encompass actual transportation conditions. To enhance both safety and standard applicability, in this study, we focused on four representative environmental conditions: temperature, vibration, shock, and low atmospheric pressure. Field measurements were conducted across road, rail, and air transport modes using a self-developed data acquisition system based on the NearLink communication technology. The measured data were then compared with the threshold values defined in current international and national standards. The results reveal that certain measured values exceeded the upper limits prescribed by existing standards, indicating limitations in their applicability under extreme transport conditions. Based on these findings, we propose revised testing parameters that better reflect actual transport risks, including a temperature cycling range of 72 ± 2 °C (high) and −40 ± 2 °C (low), a shock acceleration limit of 50 gn, adjusted peak frequencies in the vibration PSD profile, and a minimum pressure threshold of 11.6 kPa. These results provide a scientific basis for optimising safety standards and improving the safety of lithium-ion battery transportation.

Suggested Citation

  • Yihan Pan & Xingliang Liu & Jinzhong Wu & Haocheng Zhou & Lina Zhu, 2025. "Assessing Lithium-Ion Battery Safety Under Extreme Transport Conditions: A Comparative Study of Measured and Standardised Parameters," Energies, MDPI, vol. 18(15), pages 1-17, August.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:15:p:4144-:d:1717620
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    References listed on IDEAS

    as
    1. Genwei Wang & Xuanfu Guo & Jingyi Chen & Pengfei Han & Qiliang Su & Meiqing Guo & Bin Wang & Hui Song, 2023. "Safety Performance and Failure Criteria of Lithium-Ion Batteries under Mechanical Abuse," Energies, MDPI, vol. 16(17), pages 1-25, September.
    2. Feng, Xuning & Zheng, Siqi & Ren, Dongsheng & He, Xiangming & Wang, Li & Cui, Hao & Liu, Xiang & Jin, Changyong & Zhang, Fangshu & Xu, Chengshan & Hsu, Hungjen & Gao, Shang & Chen, Tianyu & Li, Yalun , 2019. "Investigating the thermal runaway mechanisms of lithium-ion batteries based on thermal analysis database," Applied Energy, Elsevier, vol. 246(C), pages 53-64.
    3. Amer Hammami & Nathalie Raymond & Michel Armand, 2003. "Runaway risk of forming toxic compounds," Nature, Nature, vol. 424(6949), pages 635-636, August.
    4. Anna Kwasiborska & Sylwia Ścigaj, 2025. "Assessment of the Risks Associated with the Handling and Transportation of Air Shipments Containing Lithium-Ion Batteries," Energies, MDPI, vol. 18(6), pages 1-20, March.
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