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Developing safe and high-performance lithium-ion batteries: Strategies and approaches

Guanjun Chen Orcid Logo, Rui Tan Orcid Logo, Chunlin Zeng, Yan Li, Zexin Zou, Hansen Wang, Chuying Ouyang, Jiayu Wan Orcid Logo, Jinlong Yang Orcid Logo

Progress in Materials Science, Volume: 154, Start page: 101516

Swansea University Author: Rui Tan Orcid Logo

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DOI (Published version): 10.1016/j.pmatsci.2025.101516

Abstract

Lithium-ion batteries (LIBs) as an effective low carbon technology provide a solution for achieving NetZero emissions, in line with the Sustainable Development Goals set by the United Nations. Research efforts have been devoted to increasing the energy density and efficiency of LIBs. However, large-...

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Published in: Progress in Materials Science
ISSN: 0079-6425
Published: Elsevier BV 2025
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URI: https://cronfa.swan.ac.uk/Record/cronfa69594
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To tackle this challenge, we must gain insight into the safety features of batteries and design durable strategies by fundamentally analyzing battery thermal runaway processes. In this review, we systematically summarize the abusive indicators that may trigger the thermal issues at the macroscopic level from thermal, chemical, and mechanical perspectives, and point out failure mechanisms that correlate with each component, e.g., cathode, anode, separator, electrolyte and current collector. Beyond material innovations, we emphasize the importance of optimizing industrial-scale manufacturing, integrating regulatory frameworks through advanced battery management systems, and enhancing safety engineering from an battery external perspective. Moreover, we systematically evaluate the contributions of theoretical and computational approaches to battery safety, critically comparing physics-based, machine learning, and hybrid models, and proposing targeted improvements. 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spelling 2025-06-09T15:49:45.9634718 v2 69594 2025-05-30 Developing safe and high-performance lithium-ion batteries: Strategies and approaches 774c33a0a76a9152ca86a156b5ae26ff 0009-0001-9278-7327 Rui Tan Rui Tan true false 2025-05-30 EAAS Lithium-ion batteries (LIBs) as an effective low carbon technology provide a solution for achieving NetZero emissions, in line with the Sustainable Development Goals set by the United Nations. Research efforts have been devoted to increasing the energy density and efficiency of LIBs. However, large-scale deployment of LIBs is challenged by thermal runaway and safety problems, particularly under abusive conditions. To tackle this challenge, we must gain insight into the safety features of batteries and design durable strategies by fundamentally analyzing battery thermal runaway processes. In this review, we systematically summarize the abusive indicators that may trigger the thermal issues at the macroscopic level from thermal, chemical, and mechanical perspectives, and point out failure mechanisms that correlate with each component, e.g., cathode, anode, separator, electrolyte and current collector. Beyond material innovations, we emphasize the importance of optimizing industrial-scale manufacturing, integrating regulatory frameworks through advanced battery management systems, and enhancing safety engineering from an battery external perspective. Moreover, we systematically evaluate the contributions of theoretical and computational approaches to battery safety, critically comparing physics-based, machine learning, and hybrid models, and proposing targeted improvements. The broader implications of these safety strategies are considered in the context of environmental sustainability and recycling. Finally, we present design principles for safer, high-performance batteries and outline emerging research and industrial directions through a critical synthesis of thermal runaway mechanisms and mitigation strategies. Journal Article Progress in Materials Science 154 101516 Elsevier BV 0079-6425 Lithium-ion battery; Thermal and safety performance; Material strategy; Battery management; Industrial-scale manufacture; Theoretical simulation 1 11 2025 2025-11-01 10.1016/j.pmatsci.2025.101516 COLLEGE NANME Engineering and Applied Sciences School COLLEGE CODE EAAS Swansea University SU Library paid the OA fee (TA Institutional Deal) This work was financially supported by the National Key Research and Development Program of China (2023YFB3809300), National Natural Science Foundation of China (52172217), Guangdong Basic and Applied Basic Research Foundation (2024B1515020031), Shenzhen Science and Technology Program (20231122113443001 and ZDSYS20220527171401003), and Guangdong Testing Institute of Product Quality Supervision internal project (2023GQI09). R.T. acknowledges the support from Royal Society Chemistry (RSC), RSC Researcher Collaboration Grant (C23-8220221815) and Royce Industrial Collaboration Grant (RICP-R4-100029). 2025-06-09T15:49:45.9634718 2025-05-30T11:44:26.3560497 Faculty of Science and Engineering School of Engineering and Applied Sciences - Chemical Engineering Guanjun Chen 0009-0007-5109-3787 1 Rui Tan 0009-0001-9278-7327 2 Chunlin Zeng 3 Yan Li 4 Zexin Zou 5 Hansen Wang 6 Chuying Ouyang 7 Jiayu Wan 0000-0003-4603-3265 8 Jinlong Yang 0000-0001-6065-7272 9 69594__34433__f09360e92ce74a8095a6eedc89a41db3.pdf 69594.VoR.pdf 2025-06-09T15:43:05.9403216 Output 43818295 application/pdf Version of Record true © 2025 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license. true eng http://creativecommons.org/licenses/by/4.0/
title Developing safe and high-performance lithium-ion batteries: Strategies and approaches
spellingShingle Developing safe and high-performance lithium-ion batteries: Strategies and approaches
Rui Tan
title_short Developing safe and high-performance lithium-ion batteries: Strategies and approaches
title_full Developing safe and high-performance lithium-ion batteries: Strategies and approaches
title_fullStr Developing safe and high-performance lithium-ion batteries: Strategies and approaches
title_full_unstemmed Developing safe and high-performance lithium-ion batteries: Strategies and approaches
title_sort Developing safe and high-performance lithium-ion batteries: Strategies and approaches
author_id_str_mv 774c33a0a76a9152ca86a156b5ae26ff
author_id_fullname_str_mv 774c33a0a76a9152ca86a156b5ae26ff_***_Rui Tan
author Rui Tan
author2 Guanjun Chen
Rui Tan
Chunlin Zeng
Yan Li
Zexin Zou
Hansen Wang
Chuying Ouyang
Jiayu Wan
Jinlong Yang
format Journal article
container_title Progress in Materials Science
container_volume 154
container_start_page 101516
publishDate 2025
institution Swansea University
issn 0079-6425
doi_str_mv 10.1016/j.pmatsci.2025.101516
publisher Elsevier BV
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Chemical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Chemical Engineering
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description Lithium-ion batteries (LIBs) as an effective low carbon technology provide a solution for achieving NetZero emissions, in line with the Sustainable Development Goals set by the United Nations. Research efforts have been devoted to increasing the energy density and efficiency of LIBs. However, large-scale deployment of LIBs is challenged by thermal runaway and safety problems, particularly under abusive conditions. To tackle this challenge, we must gain insight into the safety features of batteries and design durable strategies by fundamentally analyzing battery thermal runaway processes. In this review, we systematically summarize the abusive indicators that may trigger the thermal issues at the macroscopic level from thermal, chemical, and mechanical perspectives, and point out failure mechanisms that correlate with each component, e.g., cathode, anode, separator, electrolyte and current collector. Beyond material innovations, we emphasize the importance of optimizing industrial-scale manufacturing, integrating regulatory frameworks through advanced battery management systems, and enhancing safety engineering from an battery external perspective. Moreover, we systematically evaluate the contributions of theoretical and computational approaches to battery safety, critically comparing physics-based, machine learning, and hybrid models, and proposing targeted improvements. The broader implications of these safety strategies are considered in the context of environmental sustainability and recycling. Finally, we present design principles for safer, high-performance batteries and outline emerging research and industrial directions through a critical synthesis of thermal runaway mechanisms and mitigation strategies.
published_date 2025-11-01T17:57:43Z
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