Flame-Retardant Battery Pack Case Design for Delaying Thermal Runaway: A CFD and Experimental Study

Thermal runaway (TR) in lithium-ion batteries presents a significant safety hazard for electric vehicles (EVs), often resulting in fire or explosion. Mitigating TR requires thermal-protection strategies capable of delaying or suppressing heat propagation within battery pack cases (BPCs). This study proposes a flame-retardant BPC design and evaluates its effectiveness through a combined approach using CFD-based thermal analysis and multiscale experimental validation. In the CFD model, a heat-source temperature of 1107 °C was applied to simulate the thermal load during TR, together with a coolant flow rate of 17 L/min. Material-level verification was conducted through high temperature specimen tests, in which flame-retardant pads were heated to a target of 1100 °C with an allowable tolerance of ±10% for 5 min; the unheated (backside) temperature remained below 160 °C. Full-scale assessment involved heating the BPC upper case at temperatures exceeding 500 °C for 10 min, where the backside temperature remained below 150 °C. Module-level TR experiments further confirmed that the flame-retardant layer reduced the external temperature from 240–260 °C to below 150 °C. The results demonstrate that the proposed design effectively delays thermal penetration and maintains external safety thresholds, offering practical guidelines for developing safer EV battery systems.